Multi-Coil Inductive EV Charging for Misalignment Tolerance

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Solution Overview

Problem

Existing electric vehicle (EV) charging methods using plug-in cables are bulky, prone to mechanical wear, and can cause electrical shock, while inductive charging faces inefficiencies due to misalignment and airgaps between coils.

Innovation Solution

A charging apparatus with multiple power transfer coils and a controller that detects vehicle presence and position, identifies the optimal coil to activate based on alignment signals, and adjusts for misalignments and airgaps to ensure efficient energy transfer.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If plug-in cable charging is used, then power transfer capability is sufficient, but the cable becomes bulky and difficult to manipulate

Engineering Contradiction:

Improvepower transfer capabilityVSAvoidcable manipulation

Core Design Contradiction:

PowerVSEase of operation

Solution Approach 1:

The patent replaces the mechanical plug-in cable system with an inductive wireless charging system using electromagnetic fields. The charging apparatus uses a power transfer coil that generates an alternating magnetic field to induce current in the vehicle's coil, eliminating the need for physical cable connection and manipulation while maintaining sufficient power transfer capability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Power

If plug-in cable charging is used, then power transfer capability is sufficient, but mechanical wear and electrical shock risks increase

Engineering Contradiction:

Improvepower transfer capabilityVSAvoidmechanical wear and safety

Core Design Contradiction:

PowerVSReliability

Solution Approach 1:

The patent eliminates mechanical contact by using inductive coupling between the charging apparatus coil and the vehicle coil. This wireless energy transfer method removes the mechanical wear associated with connector insertion/removal and eliminates electrical shock risks from exposed conductors, while maintaining reliable power transfer capability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Ease of operation

If inductive charging with single coil is used, then wireless charging is achieved, but misalignment and airgaps reduce charging efficiency

Engineering Contradiction:

Improvewireless chargingVSAvoidcharging efficiency

Core Design Contradiction:

Ease of operationVSLoss of energy

Solution Approach 1:

The patent divides the charging apparatus into multiple independent coils (first coil, second coil, third coil, fourth coil) arranged in a grid pattern. Each coil can be independently activated based on the vehicle's position and alignment, allowing the system to compensate for misalignment and maintain efficient energy transfer even when the vehicle is not perfectly positioned.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent implements dynamic coil selection and activation based on real-time detection of the vehicle's position and alignment. The controller activates specific coils based on alignment signals detected by sensors, allowing the charging apparatus to adapt to varying vehicle positions and maintain optimal charging efficiency throughout the charging process.

Inventive Principle:

Principle #15Dynamics

4Adaptability or versatility

If multiple power transfer coils are used, then alignment tolerance is improved, but device complexity increases

Engineering Contradiction:

Improvealignment toleranceVSAvoidcharging apparatus structure

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent divides the charging apparatus into multiple independent coils with associated alignment signal detectors. Each coil-detector pair operates semi-independently, allowing the system to handle alignment variations without requiring a completely complex unified structure. This segmented approach improves alignment tolerance while keeping individual components relatively simple.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent designs the multiple coils to be functionally equivalent and interchangeable, with each coil capable of performing the same power transfer function. This universal design allows the system to accommodate various vehicle positions and alignments using the same basic coil structure, improving adaptability without proportionally increasing structural complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution enhances the efficiency and safety of EV charging by reducing the impact of misalignments and airgaps, allowing for effective energy transfer even with slight deviations in coil alignment, and eliminating the need for bulky cables.

Implementation Method 1

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentUS20250128626A1Methods, systems, and devices for inductictive charging of vehicle batteries

Publication Date: 2025.04.24 ENERSYS DELAWARE INC

AI summary

Methods, systems, and devices for transferring energy and communications signals via inductive coupling to an on-board coil of an electric vehicle. As an example, a charging apparatus may include a plurality of power transfer coils; and a controller, configured to: detect a presence of the vehicle in a proximity of the charging apparatus; identify a power transfer coil from the plurality of power transfer coils to activate based on a position of the vehicle relative to the charging apparatus: and activate the identified power transfer coil.