Method for operating a wireless charger and a wireless charger system

TECHNICAL FIELD

The present disclosure relates to a method and a corresponding apparatus for operating a wireless charger. The present disclosure also relates to a wireless charger system and wireless power transfer system. The wireless charger is in particular configured to charge a battery of an electrically driven vehicle.

BACKGROUND

Wireless power transfer (WPT) for electrical vehicles is a contactless inductive energy transfer system. At present such systems operate with a fundamental frequency range between 79 kHz and 90 kHz as specified by international standard agencies. The magnetic field generated in wireless power transfer has a stray field component which radiates into a surrounding area and is a potential source of radio interference .

The electrical current which generates the magnetic field is itself not a perfect sine wave, and as such contains harmonics of the fundamental frequency. These harmonics fall directly in the Long Wave and Medium Wave bands used by licensed transmitters, which is of great concern to radio users and the International Telecommunications Union, ITU, who fear that radio services will be severely disrupted when wireless chargers are operating in the vicinity of radio receivers .

For solving this problem US 2015/0145341 A1 discloses a shaping of the magnetic field using magnetic topologies which have reduced stray field emissions.

It is an object of the present disclosure to provide a method and a corresponding apparatus for operating a wireless charger allowing for reducing an emitted magnetic stray field of the wireless charger and/or allowing for an improved efficiency of the wireless charger.

It is a further object of the present disclosure to provide a wireless charger system with reduced magnetic stray field emission and improved efficiency.

It is a further object of the present disclosure to provide a wireless power transfer system with reduced magnetic stray field emission and improved efficiency.

SUMMARY

According to the present disclosure, one or more of the above-mentioned objects are achieved by a method and an apparatus for operating a wireless charger according to the features of present claim 1.

One or more of the above-mentioned objects are also achieved by a wireless charger system according to the features of present claim 8 One or more of the above-mentioned objects are also achieved by a wireless power transfer system according to the features of present claim 13.

Advantageous embodiments are given in the dependent claims.

In a first and second aspect of the present disclosure, a method and an apparatus for operating a wireless charger are presented. The wireless charger comprises a multi-level converter arrangement with a first converter and at least one further converter. Each converter is configured to receive a respective control signal vector and to provide a pulse- width-modulated, pwm, output signal on its output terminals dependent on the received control signal vector. Furthermore the wireless charger comprises a power source resonator for wirelessly transmitting power to a power capture resonator. The multi-level converter arrangement is configured to provide a supply power to the power source resonator. A set of parameter records is provided and the parameter records are assigned to the individual converters. For each converter a control signal vector is generated and provided dependent on the assigned parameter record, so that the multi-level converter arrangement provides the supply power with a desired signal waveform to the power source resonator. The set of parameter records depends on the desired signal waveform of the multi-level converter arrangement. Each parameter record defines a duty-cycle and/or a phase shift angle of a converter output signal of the assigned converter and the duty-cycles and/or phase shift angles of at least two parameter records are different.

Advantageously the output voltage of the multi-level converter arrangement, i.e. the driving voltage of the wireless charging power source, has more levels and takes on a shape which is more sinusoidal, as a result of which the wave fidelity is improved and the harmonic content decreased. The shaping of the output of the multi-level converter arrangement results in a current waveform in the wireless charging coils which is very close to being a sine wave, thereby reducing the stray fields at harmonic frequencies and subsequently reducing or eliminating radio frequency interference. Furthermore not only the stray field harmonics are reduced, but also an increase in overall efficiency can be achieved, most likely due to a reduction in copper and iron losses caused by higher frequency harmonics which have been eliminated. The parameter records of the converters can be selected or determined such that an output signal of the first converter and an output signal of the at least one further converter, comprise a respective phase angle such that selected harmonics and/or total distortion are minimal.

According to embodiments of the first and second aspects, the assignment of parameter records to the converters varies over time. Advantageously this allows for loss balancing. An even distribution of the losses in the converters can be achieved.

According to embodiments of the first and second aspects, for a multi-level converter with more than three levels the assignment of the parameter records changes after every pulse-width-modulation cycle.

According to embodiments of the first and second aspects, at least one converter comprises a switching unit with two half bridge modules and each parameter record defines a duty-cycle for the respective half-bridge modules of the converter, wherein the duty-cycles of the half-bridge modules are different. Alternatively or additionally each parameter record defines a phase shift angle for the respective half bridge modules of the converter, wherein the phase shift angles of the half-bridge modules are different. The generic phase shifted PWM modulation method for N-level resonant converters is able to optimize harmonics by controlling M= (N- l)/2 number of for example bridge converters supplied for instance by a single Power Factor Correction converter (buck/boost) and for instance decoupled by isolation transformer (s).

According to embodiments of the first and second aspects, a switching frequency of the converters is controlled such that the output voltage of the multi-level converter comprises a fundamental frequency between 79 kHz and 90 kHz, according to which the wireless charging current has a fundamental frequency between 79kHz and 90kHz, which is the preferred frequency range for wireless power transfer for electric vehicles .

According to embodiments of the first and second aspects the parameter records of the converters are selected or determined based on a Fourier's series optimization with minimizing selected harmonics and/or minimizing total distortion as criterion for optimization. The parameter records of the converters are selected or determined such that an output signal of the first converter and an output signal of the at least one further converter, comprise a respective phase angle such that selected harmonics and/or total distortion are minimal.

In a third aspect of the present disclosure, a wireless charger system is presented. The wireless charger system comprises an apparatus according to the second aspect or an advantageous embodiment of the apparatus according to the second aspect. The wireless charger system furthermore comprises a wireless charger comprising a multi-level converter arrangement with a first converter and at least one further converter, each converter being configured to receive a respective control signal vector and to provide a pulse- width-modulated, pwm, output signal on its output terminals dependent on the received control signal vector. Furthermore the wireless charger comprises a power source resonator for wirelessly transmitting power to a power capture resonator.

According to embodiments of the third aspect, the multi-level converter arrangement comprises N levels and M converters, wherein N is a positive integer greater than 3 or equal to 3, and M = (N-l)/2. Compared to conventional three-level modulation, more degrees of freedom in five-level modulation or even higher, allow a reduction of distortion in the converter output voltage and current. Consecutively, the 3rd harmonic, the 5th harmonic, and/or the 9th harmonic, respectively, can be reduced in the electromagnetic field.

According to embodiments of the third aspect, the multi-level converter arrangement comprises K isolation transformers, wherein K = M-l. The presence of isolation transformers allows that there is no commutation fault between the series- connected cells and additionally, it improves the EMC performance of the whole WPT system.

According to embodiments of the third aspect, the isolation transformers are arranged between the multi-level converter arrangement and the power source resonator. According to embodiments of the third aspect, the wireless charger comprises a power correction module which is configured to supply a direct voltage to the at least two converters. Advantageously, a power factor correction is maintained. The power factor correction module has two functions, firstly to shape the grid current to near unity power factor and secondly, to provide a stable DC voltage input to the converter.

In a fourth aspect of the present disclosure, a wireless power transfer system is presented. The wireless power transfer system comprises a wireless charger system according to the third aspect or an advantageous embodiment of the wireless charger system according to the third aspect. Furthermore, the wireless power transfer system comprises a power capture resonator as well as a rectifier. The rectifier is configured to be coupled to a load.

BRIEF DESCRIPTION OF THE DRAWINGS

It is to be understood that both the foregoing general description and the following detailed description are merely exemplary, and are intended to provide an overview or framework to understand the nature and character of the claims. The accompanying drawings are included to provide a further understanding and are incorporated in, and constitute a part of, this description. The drawings illustrate one or more embodiments, and together with the description serve to explain principles and operation of the various embodiments. The same elements in different figures of the drawings are denoted by the same reference signs. The drawings are not necessarily drawn to scale but are configured to clearly illustrate the disclosure.

Fig. 1 shows a block diagram of an exemplary embodiment of a wireless charger,

Fig. 2 shows a block diagram of an exemplary embodiment of a switch unit,

Fig. 3 shows a block diagram of an exemplary embodiment of a 3-level converter with its control signals,

Fig. 4 shows an exemplary flow chart for a program to operate a wireless charger,

Figs. 5a to 5c show exemplary traces of an output signal of the multi-level converter arrangement and its first converter and a second converter,

Fig. 6 show exemplary traces of switch pulses applied to switches of the first converter and the second converter, and

Figs. 7a to 7c show exemplary voltage output traces and current output traces of respective multi-level converter arrangements as well as the corresponding spectral analysis.

DETAILED DESCRIPTION OF EMBODIMENTS

The present disclosure will now be described in greater detail hereinafter with reference to the accompanying drawings showing embodiments of the disclosure. The disclosure may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that the disclosure will fully convey the scope of the disclosure to those skilled in the art. While features of the present disclosure may be discussed relative to certain embodiments and figures below, all embodiments of the present disclosure can include one or more of the advantageous features discussed herein. In other words, while one or more embodiments may be discussed as having certain advantageous features, one or more of such features may also be used in accordance with the various embodiments of the disclosure discussed herein. In similar fashion, while exemplary embodiments may be discussed below as device, system, or method embodiments it should be understood that such exemplary embodiments can be implemented in various devices, systems, and methods.

Figure 1 shows a block diagram of a wireless power transfer system. The wireless power transfer system comprises a multi level converter arrangement, a wireless power transfer (WPT) resonance circuit, a rectifier and a load and a control unit (not shown in Figure 1). The WPT resonance circuit RES comprises a power source resonator and a power capture resonator. The wireless multi-level converter arrangement and the power source resonator are part of a wireless charger.

The power capture resonator, the rectifier and the load are preferably arranged in an electrically driven vehicle. The wireless charger is preferably arranged stationary.

In an optional embodiment the wireless charger comprises a single and/or a three phase power factor correction module, which is configured to provide a direct voltage to the converters of the multi-level converter arrangement. The power factor correction module is in particular configured to shape a grid current to near unity power factor and to provide a stable DC voltage input to the converters. Instead of the term "grid current" also the term "phase current" can be used. In a single-phase grid or a star-connected three- phase grid the grid current and a line current are equal.

The multi-level converter arrangement is configured to provide an output voltage Vcon, which is used to supply power to the wireless power transfer (WPT) resonance circuit.

The multi-level converter arrangement comprises output terminals OUT1, OUT2 adapted to provide an AC output voltage Vcon, and a plurality of at least two converters. In the present example the multi-level converter arrangement includes three converters Cl, C2, Cn. However, this is only an example. It goes without saying that any number higher than one of converters can be provided.

Each of the converters Cl, C2, Cn is adapted to produce an output voltage VI, V2, Vn that can assume one of three different voltage levels. Assuming that the converter stages Cl to Cn receive identical input voltages, these three different voltage levels are: +V', -V', or 0 (zero).

In general, a multi-level converter arrangement having a number of n converters can produce 2n+l different voltage levels of the output voltage Vcon, where these different voltage levels range from -n-V' over 0 (zero) to +n-V'.

Each converter comprises a first input converter terminal and a second input converter terminal and a first output converter terminal PI, P2, Pn and a second output converter terminal Ql, Q2, Qn. Furthermore each converter comprises a switch unit Bl, B2, Bn.

The respective switch units Bl, B2, Bn are arranged between the respective converter input terminals and the respective converter output terminals PI, Ql, P2, Q2, Pn, Qn.

Figure 2 shows an example of such a switch unit Bl, B2, Bn. The respective switch units Bl, B2, Bn comprise for instance four switches SW1, SW2, SW3, SW4 that form an H-bridge connected between the input terminals Pi', Qi' and the output terminals Pi, Qi, wherein i=l, 2, ..., n and n is the number of converters of the multi-level converter arrangement.

The switches SW1, SW2, SW3, SW4 are, for example, implemented as semiconductor switches, such as bipolar or field-effect transistors .

Figure 3 shows a multi-level converter arrangement MLC with 3 converters Cl, C2, Cn with its control signal vectors v_Sl, v_S2, v_Sn.

For controlling the switch units Bl, B2, Bn each switch unit Bl, B2, Bn is configured to receive respective control signals. In particular each switch unit Bl, B2, Bn is configured to receive a group or vector of control signals. Preferably such a control signal vector v_Sl, v_S2, v_Sn comprises four control signals, for example v_Si=(Sil, Si2, Si3, Si4) as shown in Figure 2.

As shown in Figure 3 each converter Cl, C2, Cn is configured to provide a pulse-width modulated output voltage VI, V2, Vn at its output terminals PI, Ql, P2, Q2, Pn, Qn, wherein a duty-cycle of each of these output voltages VI, V2, Vn depends on the received control signal vector v_Sl, v_S2, v_Sn.

The multi-level converter arrangement MLC is configured to provide the output voltage Vcon, which is the sum of the pulse-width modulated output voltage VI, V2, Vn of the converters Cl, C2, Cn.

For this, one of the converters Cl, C2, Cn, such as the first converter stage Cl, has a first output terminal PI connected to the first output terminal OUT1; one of the converters Cl, C2, Cn, such as the third converter stage Cn, has a second output terminal Qn connected to the second output terminal OUT2; and the other converter stages, such as the second converter C2, have their first output terminals P2, Pn connected to the second output terminals Ql, Qn-1 of another converter.

The control signals of the control signal vectors v_Sl, v_S2, v_Sn are provided by the control unit, which can also be named apparatus for operating a wireless charger. The control unit is adapted to generate the control signals of the control signal vectors v_Sl, v_S2, v_Sn for example such that the output voltage Vcon is an oscillating voltage. The output voltage Vcon is the sum of the individual output voltages VI, V2, Vn of the individual converters Cl, C2, Cn.

By selecting a suitable time sequence of the individual voltage levels of the different converters Cl, C2, Cn the output voltage Vcon of the multi-level converter arrangement can approximate a time-continuous signal, in particular a continuous oscillating signal, such as a signal having a sinusoidal wave form.

Fig. 4 shows an exemplary flow chart for a program for operating a wireless charger. The program may be executed by the control unit.

In a step S10 the program is started. During starting the program variables and/or objects may be initialized.

In a step S30 a set of parameter records HB1, HB2, HBn are provided, wherein the set of parameter records HB1, HB2, HBn depends on a desired output voltage waveform of the multi level converter arrangement MLC.

Each parameter record HB1, HB2, HBn defines a duty-cycle and/or a phase shift angle d of a converter output signal VI, V2, Vn, and the duty-cycles and/or phase shift angles d of at least two parameter records HB1, HB2, HBn are different.

In the embodiment illustrated in FIG. 5a the output voltage Vcon of the multi-level converter arrangement MLC that is to be approximated is a sinusoidal voltage. A sinusoidal voltage has two half-cycles: a positive half-cycle, and a negative half-cycle, each having a time period T/2. Preferably a pulse-width-modulation duty-cycle is equal to the period length of the to-be-approximated periodic voltage.

In the embodiment of Figures 5a to 5c two converters are used to provide the output voltage Vcon of the multi-level converter arrangement MLC. Figure 5b shows an exemplary trace of the output voltage VI of a first converter Cl, and Figure 5c shows an exemplary trace of the output voltage V2 of a second converter C2.

The sinusoidal signal waveform is obtained by superimposing the output voltages Vl-Vn of the individual converters Cl,

C2, Cn, for example by superimposing the output voltages VI, V2 of the first and second converters Cl, C2. Generation of the sinusoidal output voltage Vcon during the positive half cycle will now be explained. Generation of the output signal Vcon during the negative half-cycle is equivalent to the difference that the output voltages Vl-Vn of the converter stages are positive voltages during the positive half cycle, and are negative voltages during the negative half-cycle.

The duty-cycles of the individual output voltages Vl-Vn are set by the control circuit via the control signal vectors v_Sl, v_S2 and v_Sn. Referring to the explanation hereinabove the output voltages VI, V2, Vn of the converter stages Cl,

C2, Cn that are superposed to generate the output voltage Vcon are each defined by a parameter record that, besides others (such as switch-on and switch-off times), defines the duty cycle and/or phase shift angles d of the output voltages VI, V2, Vn. Given a desired output voltage, and given a number of converter stages, the control circuit is configured to provide a set of parameter records HB1, HB2, HBn with a number of parameter records being equal to the number of converters Cl, C2, Cn. These parameter records may, for example, be provided by calculating, or by reading stored parameter record values from a storage device.

Further, given a particular parameter record set for a given converter, for example for the first converter, the control unit is adapted to generate the control signal vector v_Sl of the converter Cl such that the first converter Cl generates the output voltage VI in accordance with the assigned parameter record HBx, which is selected from the set of parameter records.

In a step S50 the parameter records HB1, HB2, HBn are assigned to the individual converters Cl, C2, Cn. In an optional embodiment the assignment of parameter records HB1, HB2, HBn to the converters Cl, C2, Cn varies over time.

Table 1 shows for different converter levels how the assignment of the parameter records HB1, HB2, HBn may vary. In Table 1 HB1 represents a first parameter record and HB2 represents a second parameter record, etc. For each converter level each line of Table 1 from the third column corresponds to one converter. Thus, for a multi-level converter arrangement with five levels during a first pulse-width- modulation cycle the first converter is assigned the first parameter record HB1 and in a second pulse-width-modulation cycle the second parameter record HB2. Furthermore, in the first pulse-width-modulation cycle the second converter is assigned the second parameter record HB2 and in the second pulse-width-modulation cycle the first parameter record HB1. For the further pulse-width-modulation cycle this scheme is repeated.

Table 1: Assignment of parameter records to converters

In a step S70 the control signals of the control signal vectors v_Sl, v_S2, v_Sn are generated such that the output signals VI, V2, Vn of the converters Cl, C2, Cn, in particular the output voltages of the respective converters Cl, C2, Cn are in correspondence with the assigned parameter record HB1, HB2, HBn.

This different assignment of parameter records HB1, HB2, HBn can also be recognized in Figure 5b and Figure 5c. Figures 5b and 5c show exemplary traces of the output signal VI, V2 of the first converter and the second converter. In Figures 5a to 5c a PWM cycle lasts 12.5 ps. As the first converter Cl is assigned in the first PWM cycle the first parameter record HB1 and in the second PWM cycle the second parameter record HB2, the duty cycles of the output voltage VI of the first converter in the first and the second PWM cycles are different. The trace of the output voltage VI of the first converter repeats every two PWM cycles. The output voltage V2 of the second converter C2 is equal to the output voltage VI of the first converter Cl, but with an offset, in particular with the offset of one PWM cycle.

In an optional embodiment the converters Cl, C2, Cn are synchronised. For instance every two PWM cycles there is a synchronising signal applied to the converters Cl, C2, Cn.

Also the duty-cycles and/or the phase-shift angles of the control signals Sil, Si2, Si3, Si4 of the respective converters Cl, C2, Cn may be defined by the parameter records HB1, HB2, HBn.

For instance, the converters Cl, C2, Cn of the multi-level converter arrangement MLC each comprise a switching unit Bl, B2, Bn with two half-bridge modules and each parameter record HB1, HB2, HBn defines a duty-cycles for the half-bridge modules of the respective converter Cl, C2, Cn, wherein the duty-cycles of the half-bridge modules are different. Alternatively or additionally each parameter record HB1, HB2, HBn defines a phase shift angle for the respective half bridge modules of the converters Cl, C2, Cn, wherein the phase shift angles of the half-bridge modules are different.

In the exemplary embodiment of Figure 6 two converters are used to provide the output voltage Vcon of the multi-level converter arrangement MLC. Figure 6 shows exemplary traces of switch pulses applied to the switches SW1, SW4of the first converter Cl and the second converter C2, which cause the first converter Cl and the second converter to provide the output signals VI, V2 and finally the output voltage Vcon of the multi-level converter arrangement MLC shown in Figures 5a to 5c.

The following system parameters may be used:

Operation frequency [79 ... 90 kHz] freq = 85 kHz

Pulse period Tp = 1/freq

Duty cycle [0 ... 180 deg] D = 0.5

On-Time Ton = D*Tp

Off-Time Toff = Tp-Ton

Dead-Time Tdead [ns]

Phase Cl [0 ... 180 deg] phasel = 0...0.5

Phase C2 [0 ... 180 deg] phase2 = 0...0.5

Phase 1 period Tphasel = phasel*Tp

Phase 2 period Tphase2 = phase2*Tp

Delay time phase 1/2 Tdelay = 0.5*(phasel- phase2)*Tp

Phase angels "Phase Cl" and "Phase C2" are for example selected based on a Fourier's series optimization with minimizing selected harmonics and/or minimizing total distortion in the output quantities (voltage or current) as criterion for optimization.

In Table 2 for a wireless power transfer charging system applying a 3-level modulation, a 5-level modulation, 7-level modulation and a 9-level modulation the different harmonics are listed comparatively. The wireless power transfer charging system is for example configured to provide 11 kW.

A normalized primary current (Norm. Pri. Curr) serves as a comparative value. As can be seen in Table 2, for example the 3 ^rd harmonic is reduced from 4.71E-02 (3-level modulation) to 0.656E-02 (5-level modulation) or 0.647E-02 (7-level modulation or 0.623E-02 (9-level modulation). Table 2: Comparison of individual harmonics reduction In Table 3 a comparison of the Total Harmonic Distortion (THD) of a wireless power transfer charging system applying a 3-level modulation, a 5-level modulation, 7-level modulation and a 9-level modulation is provided.

Table 3: Harmonics reduction

Compared to conventional three-level modulation, more degrees of freedom in N-level modulation allow a significant reduction of the distortion in the converter output voltage and current, as shown in Tables 3 and 4, while still maintaining similar efficiency irrespective of the number of converters used (Table 3).

Figures 7a to 7d show voltage output traces and current output traces of a respective multi-level converter arrangement as well as the corresponding spectral analysis for the wireless power transfer system (Figure 7a 3-level modulation, Figure 7b 5-level modulation, Figure 7c 7-level modulation and Figure 7d 9-level modulation).

Furthermore, an increase in overall efficiency is most likely due to a reduction in copper and iron losses caused by higher frequency harmonics which have been eliminated as shown in Table 4. Table 4 shows the efficiency gain and the harmonic reduction under different operating conditions when the harmonic reduction mechanism is activated (ON) or deactivated (off). Table 4: Efficiency gain and harmonics reduction

In Table 4 the unity of the field level is given in micro Tesla (mT). The field level characterises the radiated emission level measured in close proximity to the WPT coils.

REFERENCE SIGNS

PFC power correction module

Bl, B2, Bn switching unit MLC multi-level converter arrangement

OUT1, OUT2 first and second output terminal Vcon output voltage of multi-level converter arrangement

TRANS isolation transformers

RES WPT resonance circuit

PSR power source resonator

PCR power capture resonator

RX rectifier

LOAD load

Cl, C2, Ci, Cn converter VI, V2, Vi, Vn output signal of converter PI, P2, Pi, Pn converter output terminals Ql, Q2, Qi, Qn converter output terminals Pi' converter input terminal

Qi' converter input terminal v_S1, v_S2, v_Si, v_Sn control signal vector Sil, Si2, Si3, Si4 control signals SW1, SW2, SW3, SW4 switches S10,..., S90 program step T pulse-modulation cycle d phase shift angle

Icon Output current of multi-level converter arrangement

Scon Output signal spectrum of multi ^¬ level converter arrangement

WPT_C wireless charger

HB1, HB2, HBn parameter record