Wireless EV Power Transfer Control for Fast Fault Shutdown

Solution Overview

Problem

Current wireless inductive power transfer systems for electric vehicles face reliability issues, particularly in safety control functionalities such as rapid shut-down during faults, and struggle to maintain efficient power transfer according to a set power profile.

Innovation Solution

A power transfer system with a control architecture that includes transmitter-side and receiver-side controllers capable of communicating through a wireless channel, implementing closed-loop control to manage DC and AC power stages, ensuring fast responsive control functionalities and safe operation by processing signals indicative of desired and measured power values.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If closed-loop control architecture is implemented to control power transfer according to charging profile, then power transfer efficiency is improved, but system reliability deteriorates due to poor safety control functionalities

Engineering Contradiction:

Improvepower transfer efficiencyVSAvoidsafety control functionality

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The control system is divided into two independent sections: a transmitter-side section with transmitter coil and power supply system, and a receiver-side section with receiver coil and power conversion system. Each section has its own controller that operates independently, eliminating the single point of failure in centralized control and improving safety control functionality while maintaining power transfer efficiency.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A wireless communication channel acts as an intermediary between the transmitter-side and receiver-side controllers. This intermediary enables coordination and data exchange between the two independent control sections without requiring direct physical connection, allowing each controller to maintain independent operation while still achieving coordinated power transfer control.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If rapid shut-down functionality is implemented for safety control, then safety reliability is improved, but system complexity increases

Engineering Contradiction:

Improvesafety control functionalityVSAvoidcontrol architecture complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The control system is divided into two independent sections: a transmitter-side section with transmitter coil and power supply system, and a receiver-side section with receiver coil and power conversion system. Each section has its own controller that operates independently, eliminating the single point of failure in centralized control and improving safety control functionality.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Each controller (transmitter-side and receiver-side) is equipped with autonomous decision-making capability to detect faults and execute rapid shut-down independently without requiring complex inter-controller communication for safety decisions. This self-service approach simplifies the control architecture while maintaining high safety reliability.

Inventive Principle:

Principle #25Self-service

3Ease of operation

If wireless communication channel is used for controller communication, then system ease of operation is improved, but communication reliability deteriorates

Engineering Contradiction:

Improvecontroller communicationVSAvoidcommunication reliability

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

A wireless communication channel acts as an intermediary between the transmitter-side and receiver-side controllers. This intermediary enables coordination and data exchange between the two independent control sections without requiring direct physical connection, allowing each controller to maintain independent operation while still achieving coordinated power transfer control.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The control architecture dynamically adapts to communication conditions by allowing controllers to operate independently when communication is unreliable or unavailable. The system can maintain safe operation with reduced functionality rather than requiring perfect communication, thus improving communication reliability in practical wireless environments.

Inventive Principle:

Principle #15Dynamics

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 system ensures reliable and efficient power transfer to the vehicle battery, adhering to a specified profile, while providing rapid shut-down capabilities and maintaining safety control functionalities, thus enhancing reliability and ease of industrial production.

Implementation Method 1

an AC current flowing in the winding of the transmitter coil produces a magnetic flux making an induced AC current to flow in the winding of the receiver coil

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentUS11919406B2Power transfer system for electric vehicles and a control method thereof

Publication Date: 2024.03.05 ABB E-MOBILITY BV

AI summary

Power transfer system for supplying electric power to a battery of an electric vehicle including a control architecture capable of controlling the transmission of electric power to a battery of said electric vehicle and, at the same time, capable of providing fast responsive control functionalities. In a further aspect, the application relates to a method for controlling a power transfer system.