Primary-Side DC-DC Converter for Wireless EV Battery Charging
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Solution Overview
Problem
Cableless battery charging systems for electric vehicles face challenges in reliable data transmission and equipment complexity, particularly in split charging systems where wireless data transmission is difficult and secondary-side DC/DC converters add complexity.
Innovation Solution
A battery charging system with a primary-side power control arrangement that controls the charging current indirectly, using primary-side current and voltage measurements, and eliminates the need for a secondary-side DC/DC converter, relying on secondary-side sensors for calibration and monitoring to maintain a predefined charging curve with minimal calibration time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a split battery charging system with wireless data transmission is used, then cableless charging is achieved, but reliable data transmission becomes difficult to implement
Solution Approach 1:
The patent introduces a mediator approach by using the transformer coupling not only for power transfer but also for data transmission. The data is transmitted through the magnetic coupling of the transformer, avoiding the need for separate wireless communication channels while maintaining reliability through the established power transfer pathway.
Solution Approach 2:
The transformer is designed to serve multiple functions: both power transfer and data transmission. By embedding data transmission capabilities within the power transfer infrastructure, the system avoids adding separate communication hardware, thereby maintaining reliability while achieving cableless operation.
2Adaptability or versatility
If a secondary-side DC/DC converter is added to a split charging system, then charging control flexibility is improved, but equipment complexity increases
Solution Approach 1:
The patent extracts the DC/DC converter from the secondary side and relocates it to the primary side. This extraction eliminates the complexity of having a converter on the secondary side while maintaining charging control flexibility through the primary-side controller that can regulate the transformer coupling and power transfer characteristics.
Solution Approach 2:
Instead of placing the DC/DC converter on the secondary side as in conventional designs, the patent inverts the approach by implementing the conversion function on the primary side. This inversion simplifies the secondary side architecture while preserving adaptability through intelligent primary-side control of the magnetic coupling.
3Measurement precision
If current and voltage sensors are placed on both primary and secondary sides, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The patent implements a feedback mechanism where sensors on both sides provide measurement data to controllers that continuously monitor and adjust the charging process. This feedback loop ensures high measurement precision for safety and control while managing complexity through coordinated control algorithms that utilize the redundant sensor information efficiently.
Solution Approach 2:
The dual sensor configuration provides a safety cushion by offering redundant measurement capabilities. If one sensor or measurement path fails, the other provides backup measurement data, ensuring continuous safe operation. This beforehand cushioning justifies the added complexity by providing robust fault tolerance.
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
This approach ensures precise and reliable charging with reduced equipment complexity, avoiding dead times and potential overloading, while maintaining a predefined charging curve with minimal calibration time, and providing robust charging operation by concentrating control components on the primary side.
Implementation Method 1
a transformer (11) having a primary winding (12) as part of the primary side and a secondary winding (13) as part of the secondary side
Data Source
AI summary
A battery charging system for cablelessly charging a battery includes a primary-side charging unit as a primary side, a secondary-side charging unit as a secondary side, a transformer having a primary-side winding as part of the primary side and a secondary-side winding as part of the secondary side, one controller on the primary side and one controller on the secondary side, one voltage sensor on the primary side and one voltage sensor on the secondary side, one current sensor on the primary side and one current sensor on the secondary side, one communication unit on the primary side and one communication unit on the secondary side, and one direct current converter provided on the primary side only.