Abstract:
An apparatus and method efficiently integrating inductive and conductive charging systems, including embodiments directed towards enabling user selection of either, or both, of conductive and inductive charging. Conductive charging and inductive charging both have, in certain contexts or when judged by different criteria, advantages over the other. Systems and methods relying on one or the other would not have as wide-spread value to a user with opportunities to access both types of charging modalities.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    The present invention relates generally to charging an energy storage system, and more particularly but not exclusively, to an integrated charging system employing both conductive and inductive modes. 
         [0002]    Many high-performance energy storage solutions now employ series-connected modules that, in turn, are series and parallel combinations of individual battery cells. Battery packs used with electric vehicles store large amounts of energy in a small space, producing high energy densities. The energy is converted into mechanical energy by the power train to move the vehicle, among other uses. 
         [0003]    Conventional charging systems employ either a conductive system or an inductive system. For electric vehicle implementations, it has become a current standard to use conductive charging system for transferring energy into the energy storage system. There are some advantages to use of inductive charging systems which has resulted in after-market products to add parallel inductive charging systems. 
         [0004]    Electric vehicles are particularly known for having tight budgets on size, weight, and cost, which are often interrelated. Simply adding an entire parallel inductive charging system to a vehicle, either during manufacture or after-market risks degrading performance, safety, and reliability. 
         [0005]    What is needed is an apparatus and method for efficiently integrating inductive and conductive charging systems. 
       BRIEF SUMMARY OF THE INVENTION 
       [0006]    Disclosed is an apparatus and method efficiently integrating inductive and conductive charging systems. The present invention includes embodiments directed towards enabling user (or automatic) selection of either, or both, of conductive and inductive charging. Conductive charging and inductive charging both have, in certain contexts or when judged by different criteria, advantages over the other. Systems and methods relying on one or the other would not have as wide-spread value to a user with opportunities to access both types of charging modalities. Embodiments of the present invention advantageously merge and integrate both modalities to reduce added complexity, size, and weight while preserving efficiency and improving usefulness. Disclosed are systems and methods for integrated conductive and inductive charging. A charging system for an energy storage system of an apparatus includes a conductive rectifier stage wholly disposed on the apparatus, the conductive rectifier stage including a first inverter switching circuit coupled to a first primary winding of an isolation transformer and a first output smoothing circuit coupled to both a first secondary winding of the isolation transformer and to the energy storage system, the conductive rectifier stage rectifying a first AC line voltage conductively received at the apparatus wherein the first inverter switching circuit is responsive to a first control signal; a partial inductive rectifier stage wholly disposed on the apparatus, the partial inductive rectifier stage part of an inductive rectifier stage partially disposed on the apparatus, the inductive rectifier stage including a second inverter switching circuit coupled to a second primary winding of an induction transformer and a second output smoothing circuit coupled to both a second secondary winding of the induction transformer and to the energy storage system, the inductive rectifier stage rectifying a second AC line voltage not conductively received at the apparatus wherein the second inverter switching circuit is wholly disposed off the apparatus and wherein the second inverter switching circuit is responsive to a second control signal; and a controller communicated to the rectifier stages to provide the first control signal and the second control signal. 
         [0007]    A charging method for an energy storage system of an apparatus includes a) rectifying a first AC line voltage conductively received at the apparatus using a conductive rectifier stage wholly disposed on the apparatus, the conductive rectifier stage including a first inverter switching circuit coupled to a first primary winding of an isolation transformer and a first output smoothing circuit coupled to both a first secondary winding of the isolation transformer and to the energy storage system wherein the first inverter switching circuit is responsive to a first control signal; b) rectifying a second AC line voltage not conductively received at the apparatus using an inductive rectifier stage partially disposed on the apparatus, the inductive rectifier stage including a second inverter switching circuit coupled to a second primary winding of an induction transformer and a second output smoothing circuit coupled to both a second secondary winding of the induction transformer and to the energy storage system wherein the second inverter switching circuit is wholly disposed off the apparatus and wherein the second inverter switching circuit is responsive to a second control signal; and c) communicating the control signals to the inverter switching circuits from a controller having a master controller wholly disposed on the apparatus. 
         [0008]    A charging method for an energy storage system of an apparatus includes a) evaluating whether a conductive rectifier stage wholly disposed on the apparatus is energized from a first AC line voltage wherein the conductive rectifier stage includes a first output smoothing circuit including a plurality of components; b) evaluating whether an inductive rectifier stage partially disposed on the apparatus is energized from a second AC line voltage wherein a second output smoothing circuit of the inductive rectifier stage disposed on the apparatus is coupled to the first output smoothing circuit and shares at least one component of the plurality of components; and c) charging the energy storage system using any rectifier stage that has evaluated as being energized. 
         [0009]    Features/benefits include a user to employ any available charging solution, whether it is a conductive charger and/or an inductive charger when charging an energy storage solution such as battery packs used in electric vehicles and similar applications. Other features, benefits, and advantages of the present invention will be apparent upon a review of the present disclosure, including the specification, drawings, and claims. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0010]    The accompanying figures, in which like reference numerals refer to identical or functionally-similar elements throughout the separate views and which are incorporated in and form a part of the specification, further illustrate the present invention and, together with the detailed description of the invention, serve to explain the principles of the present invention. 
           [0011]      FIG. 1  illustrates a first implementation of an integrated conductive and inductive charging solution; 
           [0012]      FIG. 2  illustrates a second implementation of an integrated conductive and inductive charging solution; and 
           [0013]      FIG. 3  illustrates a charging process for an integrated conductive and inductive charging solution. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0014]    Embodiments of the present invention provide an apparatus and method for efficiently integrating inductive and conductive charging systems. The following description is presented to enable one of ordinary skill in the art to make and use the invention and is provided in the context of a patent application and its requirements. 
         [0015]    Various modifications to the preferred embodiment and the generic principles and features described herein will be readily apparent to those skilled in the art. Thus, the present invention is not intended to be limited to the embodiment shown but is to be accorded the widest scope consistent with the principles and features described herein. 
         [0016]      FIG. 1  illustrates a first implementation of an integrated conductive and inductive charging solution  100 . Charging solution  100  includes both a conductive rectifier stage and an inductive rectifier stage that have been integrated together to provide charging energy to an energy storage system (ESS, e.g., a battery, a battery module, a battery pack, and the like). Different embodiments and implementations offer differing levels of integration appropriate for the intended application, some of which are described herein. The conductive rectifier stage includes an inverter switching circuit  105  that operates in conjunction with an output smoothing circuit  110  to produce a steady DC voltage from a first AC line voltage  115 . Many implementations include an optional isolation transformer  120  to isolate the DC load of the energy storage system from first AC line voltage  115 , particularly those implementations for electric vehicle charging and telecommunications. When employed, a primary winding of isolation transformer  120  is coupled to an output of inverter switching circuit  105  and a secondary winding of isolation transformer  120  is coupled to an input of output smoothing circuit  110 . 
         [0017]    In addition, many charging solutions include a preconditioner  125  that provides any necessary/desirable switching, electromagnetic interference (EMI) filtering, and other conditioning of first AC line voltage  115  before energizing inverter switching circuit  105 . Similarly many charging solutions include a postconditioner  130  that provides any necessary/desirable switching, EMI filtering, and other conditioning of smoothed DC voltage from output smoothing circuit  110  before application to the ESS. 
         [0018]    Charging solution  100  further includes a controller  135  that generates appropriate control signals to operate inverter switching circuit  105 . There are many different types of inverter switching circuits which will have variations regarding the details of the control signals (e.g., pulse width modulation or other modulation schemes and the like) necessary for their operation, all within the scope of the present invention. Controller  135  employs a set of charging parameters gathered from a sensing system distributed throughout charging solution  100 . The set of charging parameters includes V AC  for first AC line voltage  115  measured by a voltage sensor  140  and an I AC  for current provided by first AC line voltage  115  to inverter switching circuit  105  measured by a current sensor  145 . The set of charging parameters further includes V BAT  for the ESS measured by a voltage sensor  150  and I BAT  for the ESS measured by a current sensor  155 . 
         [0019]    Output smoothing circuit  110  includes a number of components, and like inverter switching circuit  105 , there are many types and topologies of output smoothing circuit  110  which will have variations on the details necessary for their operation, all within the scope of the present invention. In the preferred embodiment, the preferred level of integration and component reuse is in the output smoothing circuits of the rectifier stages as further described herein. Thus a representative output smoothing circuit is described in more detail, with the understanding that other output smoothing circuits may vary slightly or dramatically, and all within the scope of the present invention. 
         [0020]    Output smoothing circuit  110  includes a diode bridge  160  having a pair of inputs coupled to the secondary winding and a pair of outputs coupled to opposing terminals of a capacitor  165 . A first output of diode bridge  160  is coupled to a first terminal of capacitor  165  through an inductor  170 , and a second output of diode bridge  160  is coupled to a second terminal of capacitor  165  through current sensor  155 . An optional snubber circuit  172  is coupled between outputs of diode bridge  160  and capacitor  165 . There are many different implementations and possible uses of snubber circuit  172 , such as providing protection, improving performance, and the like. In charging solution  100 , a representative snubber circuit  172  includes a snubber resistor  175  and series-coupled snubber diode  180  (cathode of snubber diode  180  is coupled to snubber resistor  175 ) is in turn coupled in parallel with inductor  170  to the first output terminal of diode bridge  160  and first terminal of capacitor  165 . A snubber capacitor  182  is coupled from the cathode of snubber diode  180  to the second output terminal of diode bridge  160 . In some embodiments, diode bridge  160  may be replaced with an active rectifier component or circuit. 
         [0021]    The inductive rectifier stage includes an off-board electronics assembly  184  that is energized by a second AC line voltage  186  and is electromagnetically coupled, using an inductive transformer  188 , to the ESS. The nature and type of coupling and level of integration varies based upon implementation and application details. Charging solution  100  provides a second inverter switching circuit as part of off-board electronics assembly  184 , with the second inverter switching circuit responsive to control signals from controller  135 . Charging solution  100  preferably includes at least some minimal secondary/slave controller functions within off-board electronics assembly  184  that is responsive to primary/master controller functions within controller  135 . In such a configuration, the controller function is distributed on-board and off-board with primary/master control functions disposed on-board. In some implementations, the on-board and off-board controller functions may be more equivalent or have other cooperative modes, including the off-board controller functions in some situations predominate. 
         [0022]    Charging solution  100  is implemented using a second output smoothing circuit  190  coupled to both a secondary winding of induction transformer  188  and to capacitor  165 . Output smoothing circuit  190  includes a diode bridge  192  having a pair of inputs coupled to the secondary winding of induction transformer  188  and a pair of outputs coupled to the opposing terminals of capacitor  165 . A first output of diode bridge  192  is coupled to the first terminal of capacitor  165  through an inductor  194 , and a second output of diode bridge  192  is coupled to the second terminal of capacitor  165  through current sensor  155 . 
         [0023]    It is a feature of charging solution  100  that the conductive rectifier stage is wholly disposed on the apparatus with the ESS (e.g., an electric vehicle) while a portion of the inductive rectifier stage is disposed on the apparatus and a portion disposed off the apparatus. Each rectifier stage is shown with its own energizing AC line voltage, but in some cases it may be that these AC line voltages are shared. The AC line voltages may be single-phase or multiphase, and may be the same voltage level (e.g., 110 VAC, 220 VAC, or the like) or provide different energization voltages (e.g., 220 VAC for first AC line voltage  115  and 110 VAC for second AC line voltage  186 ) and currents (e.g., 16 A and 40 A respectively). It is a feature of charging solution  100  that controller  135  provides operational control over both inverter switching circuits. Controller  135  is disposed on the apparatus, and in the preferred embodiments wholly disposed on the apparatus. In some implementations, some controller functions specifically required for the inductive rectifier stage or other feature may be incorporated into off-board electronics assembly  184 . Controller  135  and off-board electronics assembly  184  preferably include wireless communication modules enabling bidirectional data flow through a wireless link  196 . The data flow includes instructions for the inverter switching circuit and a set of sensor parameters for second AC line voltage  186 , including V AC  and I AC . In some implementations, controller  135  may provide battery sensor data and other operational information and off-load some tasks to off-board electronics assembly  184 . Off-board electronics assembly  184  may, in some configurations, provide higher level data, such as power available, time to complete charge, and the like, or provide information that controller  135  establishes this information. 
         [0024]    Operation of charging solution  100  will be described in a specific narrow context as an aid to understanding the present invention. The present invention includes this context, as well as other contexts. charging solution  100  is included as part of an EV and uses the conductive rectifier stage as a primary charging modality. As well-known, a user mates a physical power connector coupled to an energy source, utility grid power or the like to a complementary physical power connector on the apparatus to enable charging. Controller  135  operates inverter switching circuit  105  to produce an appropriate AC voltage level and output smoothing circuit  110  rectifies and smooths this voltage to the desired DC voltage which is applied to the ESS for charging. 
         [0025]    This is often sufficient for many applications, but it does require some work on the part of the user to engage the physical power connector and to actuate the charging process. As charging stations continue to proliferate, some will be installed with inductive charging capacity. This will be true for both private and public charging stations. In either case, when the EV is enabled for inductive charging in addition to the conductive charging capability, this provides more options to the user. It is often true that inductive charging systems are less efficient, though they can be more convenient for the user. Less efficiency typically means that, holding other variables and conditions constant, it will take longer to charge the ESS to a desired level using inductive charging than would be the case using conductive charging. In some cases this may not be inconvenient to the user, such as when a standard overnight charge at inductive charging efficiency sufficiently charges the ESS. The user is able to install off-board electronics assembly  184  in the floor of a garage, for example, drive over the off-board electronics, and initiate (automatically or manually) a charging process that will be complete the next time the EV is to be driven. 
         [0026]    In a public charging station scenario, it can be the case that the charging station includes both a conductive charging bay as well as an inductive charging bay. The user is able to select either bay in the event one or both are open, or select a queue that represents the shortest-time-to-charge based upon efficiency and number of preceding vehicles in each queue. 
         [0027]    Even when the user chooses conveniences associated with inductive charging, charging solution  100  enables the user in any of the scenarios to choose conductive charging as appropriate. This could be the case when the user, after initiating inductive charging, realizes that an unexpected use is required of the EV, and the inductive charging solution will not sufficiently charge the ESS before the EV is needed. The user is able to engage the conductive charging capacity and have the EV ready when needed. 
         [0028]    In these scenarios, independent, non-concurrent operation of the rectifiers stages is described. In some embodiments, it is possible for the user to energize both rectifier stages concurrently and achieve even greater charging speed. These various scenarios are preferably tuned and optimized by adjusting components of the output smoothing circuits. 
         [0029]    A critical component of the output smoothing circuits for concurrent operation are the inductors (i.e., inductor  170  and inductor  194 ). In  FIG. 1 , each smoothing circuit has its own inductor (i.e., inductor  170  and inductor  194 ) that is sized to store and discharge energy responsive to a maximum instantaneous power provided by each output smoothing circuit, without concurrent operation of the rectifier stages. By doing this, each rectifier stage is able to operate concurrently and independently, each inductor sized properly. As noted herein, typically inductive rectification is less efficient than conductive rectification. In such cases, when each rectifier stage is energized by similar AC line voltages, inductor  194  may be sized smaller (and thus be less costly) than inductor  170 . It should be noted that in some implementations, charging solution  100  dispenses with inductor  170  and inductor  194 . 
         [0030]    In some implementations it is necessary or desirable to use a single inductor yet enable the possibility of concurrent operation. In such cases it is possible to eliminate inductor  194  by increasing the size of inductor  170  to store/discharge a maximum instantaneous power provided by both output smoothing circuits. It may be less costly, or otherwise advantageous, to use a single larger inductor than two smaller inductors. Of course, elimination of inductor  194  may require rerouting of the connections shown to properly use inductor  170  with output smoothing circuit  190 . 
         [0031]    In other implementations it is necessary or preferable to prevent both rectifier stages from operating concurrently. In such cases it is also possible to use a single shared inductor, but it need be sized based upon the maximum instantaneous power of the output smoothing circuit discharging the greatest instantaneous power. Typically this will be the output smoothing circuit associated with the conductive rectifier stage. 
         [0032]      FIG. 2  illustrates a second implementation of an integrated conductive and inductive charging solution  200 . Charging solution  200  substitutes a modified output circuit  205  of the inductive rectifier stage for output smoothing circuit  190  shown in  FIG. 1 . Output circuit  205  is coupled directly to the secondary winding of isolation transformer  120  at the inputs of diode bridge  160 . Output circuit  205  of the preferred embodiment includes a power connector and relays/contactors that selectively couple the secondary winding of inductive transformer  188  to diode bridge  160 . In some cases, it may be necessary or desirable to provide an additional set of relays coupled to the secondary winding of isolation transformer  120  to not short inductive transformer  188  during inductive charging. This configuration uses output smoothing circuit  110  for both rectifier stages. Note that in this configuration implementation there is no concurrent operation of the rectifier stages. In some instances it may be possible to enable concurrent operation by adjustment to one or both of the output circuits. Other arrangements and intercoupling of components in the stages are also possible in other embodiments to share differing numbers of components, based upon needs, performance, and resource costs. 
         [0033]      FIG. 3  illustrates a charging process  300  for an integrated conductive and inductive charging solution. Process  300  is preferably implemented automatically by controller  135  (typically with cooperation from controller functions disposed in off-board electronics assembly  184 ). Process  300  evaluates whether the conductive rectifier stage is energizable at step  305  and evaluates whether the inductive rectifier stage is energizable at step  310 . Finally at step  315  process  300  energizes any (or both) rectifier stages that are energizable, as appropriate. 
         [0034]    There are many different topologies and configurations for rectifier stages in general and the inverter switching circuits and output smoothing circuits specifically. The present invention is adaptable to many, if not all of these, and offers conveniences and flexibility to users. The present invention is not limited to mobile apparatus having rechargeable energy storage systems. There are mobile inductive charging stations that employ paddles, for example, that could be used in cooperation with a non-mobile apparatus having a primary conductive rectifier stage. 
         [0035]    An aspect of the present invention addresses efficiently coupling the off-board electronics assembly to the apparatus and improve inductive charging efficiency. The off-board electronics assembly may be integrated into a floor of charging station, or may be disposed on the floor and a ramp provided to aid in alignment. In some implementations, particularly for public charging stations, robotic systems may move and reposition the off-board electronics assembly to optimize electromagnetic coupling. Those robotic systems may be disposed in the charging station, the vehicle, or both. 
         [0036]    The systems and methods are preferably implemented using a microprocessor executing program instructions from a memory, the instructions causing the apparatus to perform as described herein. The system and methods above has been described in general terms as an aid to understanding details of preferred embodiments of the present invention. In the description herein, numerous specific details are provided, such as examples of components and/or methods, to provide a thorough understanding of embodiments of the present invention. One skilled in the relevant art will recognize, however, that an embodiment of the invention can be practiced without one or more of the specific details, or with other apparatus, systems, assemblies, methods, components, materials, parts, and/or the like. In other instances, well-known structures, materials, or operations are not specifically shown or described in detail to avoid obscuring aspects of embodiments of the present invention. 
         [0037]    Reference throughout this specification to “one embodiment”, “an embodiment”, or “a specific embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention and not necessarily in all embodiments. Thus, respective appearances of the phrases “in one embodiment”, “in an embodiment”, or “in a specific embodiment” in various places throughout this specification are not necessarily referring to the same embodiment. Furthermore, the particular features, structures, or characteristics of any specific embodiment of the present invention may be combined in any suitable manner with one or more other embodiments. It is to be understood that other variations and modifications of the embodiments of the present invention described and illustrated herein are possible in light of the teachings herein and are to be considered as part of the spirit and scope of the present invention. 
         [0038]    It will also be appreciated that one or more of the elements depicted in the drawings/figures can also be implemented in a more separated or integrated manner, or even removed or rendered as inoperable in certain cases, as is useful in accordance with a particular application. 
         [0039]    Additionally, any signal arrows in the drawings/Figures should be considered only as exemplary, and not limiting, unless otherwise specifically noted. Furthermore, the term “or” as used herein is generally intended to mean “and/or” unless otherwise indicated. Combinations of components or steps will also be considered as being noted, where terminology is foreseen as rendering the ability to separate or combine is unclear. 
         [0040]    As used in the description herein and throughout the claims that follow, “a”, “an”, and “the” includes plural references unless the context clearly dictates otherwise. Also, as used in the description herein and throughout the claims that follow, the meaning of “in” includes “in” and “on” unless the context clearly dictates otherwise. 
         [0041]    The foregoing description of illustrated embodiments of the present invention, including what is described in the Abstract, is not intended to be exhaustive or to limit the invention to the precise forms disclosed herein. While specific embodiments of, and examples for, the invention are described herein for illustrative purposes only, various equivalent modifications are possible within the spirit and scope of the present invention, as those skilled in the relevant art will recognize and appreciate. As indicated, these modifications may be made to the present invention in light of the foregoing description of illustrated embodiments of the present invention and are to be included within the spirit and scope of the present invention. 
         [0042]    Thus, while the present invention has been described herein with reference to particular embodiments thereof, a latitude of modification, various changes and substitutions are intended in the foregoing disclosures, and it will be appreciated that in some instances some features of embodiments of the invention will be employed without a corresponding use of other features without departing from the scope and spirit of the invention as set forth. Therefore, many modifications may be made to adapt a particular situation or material to the essential scope and spirit of the present invention. It is intended that the invention not be limited to the particular terms used in following claims and/or to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include any and all embodiments and equivalents falling within the scope of the appended claims. Thus, the scope of the invention is to be determined solely by the appended claims.