Universal Charger for Conductive and Inductive EV Energy Transfer

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Solution Overview

Problem

Existing electric vehicle charging systems require multiple components and complex setups for both conductive and inductive charging, lacking a unified solution that minimizes components while ensuring efficient energy transfer and control.

Innovation Solution

A charger system designed to work with both conductive and inductive modes using a single charger unit, equipped with a controller and rectifiers, which can be plugged into either a stationary or mobile adapter for energy transfer to a handset with energy storage and secondary winding, allowing for efficient energy regulation and control without additional power electronics.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If separate chargers are used for conductive and inductive charging, then each charging mode can be optimized independently, but the device complexity and number of components increase

Engineering Contradiction:
Improvecharging control reliabilityVSAvoidcharger system complexity
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The charger is designed with a universal controller that can operate in both conductive and inductive charging modes using the same power electronics circuitry. The controller automatically detects the charging mode and adjusts its control algorithm accordingly, allowing a single charger to perform multiple functions without requiring separate dedicated chargers for each mode.

Inventive Principle:
Principle #6Universality (Multi-functionality)

Solution Approach 2:

The control algorithm dynamically adapts based on the detected charging mode. The controller switches between different control strategies - using rectifier control for conductive charging and resonant frequency control for inductive charging - while maintaining a unified hardware platform. This dynamic adaptation allows reliable charging control without duplicating hardware components.

Inventive Principle:
Principle #15Dynamics

2Device complexity

If a single charger is used for both conductive and inductive charging, then component complexity is reduced, but the control and regulation become more difficult

Engineering Contradiction:
Improvecharger system complexityVSAvoidcharging parameter control difficulty
Core Design Contradiction:
Device complexityVSDifficulty of detecting and measuring

Solution Approach 1:

The charger incorporates feedback mechanisms that continuously monitor charging parameters such as current, voltage, and power consumption. The controller uses this feedback information to automatically adjust its output and maintain optimal charging conditions regardless of whether it is operating in conductive or inductive mode. This feedback loop simplifies the control difficulty by providing real-time information about the charging state.

Inventive Principle:
Principle #23Feedback

Solution Approach 2:

The controller dynamically changes operating parameters such as switching frequency, duty cycle, and resonant frequency based on the detected charging mode and load conditions. By automatically adjusting these parameters, the system maintains efficient and reliable charging control without requiring complex manual intervention or separate dedicated control systems for each mode.

Inventive Principle:
Principle #35Parameter changes

3Loss of energy

If the charger is designed with mode-specific power electronics, then each charging mode achieves optimal efficiency, but the quantity of components and cost increase

Engineering Contradiction:
Improvecharging efficiencyVSAvoidnumber of components
Core Design Contradiction:
Loss of energyVSQuantity of substance

Solution Approach 1:

The power electronics circuits for both conductive and inductive charging are merged into a single unified system. The same rectifier bridge, filter capacitors, and control circuitry are used for both charging modes, eliminating the need for duplicate components. This merging maintains charging efficiency by using optimized circuit designs while significantly reducing the total quantity of components required.

Inventive Principle:
Principle #5Merging (Combining)

Solution Approach 2:

The power electronics are designed with universal components that can operate efficiently in both conductive and inductive modes. The rectifier circuit and power switching elements are configured to handle both charging methods with minimal efficiency loss, allowing the system to maintain optimal charging efficiency without requiring mode-specific hardware components.

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

Enables efficient and controlled energy transfer to electric vehicles using either conductive or inductive methods with a single charger, reducing component complexity and maintaining high efficiency across different charging positions and coupling strengths.

Implementation Method 1

the charger (20) can be plugged into a first plug adapter (21) for conductive energy transfer to the handset (24)

Methodology Applied
Scientific EffectElectrical conduction: Conduction (electrical)

Implementation Method 2

the charger (20) can be plugged into a second plug adapter (23) for inductive energy transfer to the handset (24)

Methodology Applied
Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentEP3697641B1System and method for transmitting energy to a mobile part configured as a vehicle, comprising an energy store and a secondary winding
Publication Date: 2023.12.06 SEW EURODRIVE GMBH & CO KG
  • EP3697641B1 patent drawingFigure 1
  • EP3697641B1 patent drawingFigure 2
  • EP3697641B1 patent drawingFigure 3

AI summary

The invention relates to a system for transmitting energy to a mobile part, comprising an energy store and a secondary winding. The system has a charging device, and the charging device can either be plugged to a first plug adapter in order to conductively transmit energy to the mobile part or the charging device can be plugged to a second plug adapter in order to inductively transmit energy to the mobile part, in particular the charging device can be plugged either into a first plug adapter or into a second plug adapter, wherein the first plug adapter is arranged in or on the mobile part, and the second plug adapter is arranged in a stationary manner, in particular on the outside of the mobile part.