阅读说明：本技术 无线功率传输系统 (Wireless power transmission system ) 是由 于立军 于 2020-04-02 设计创作，主要内容包括：本文描述了一种用于无线功率传输的充电单元。该充电单元包括用于感应功率传输的至少一个线圈,具有用于感测至少一个外来物体的存在的感测场的传感器线圈阵列,以及控制器。该控制器被配置为移动该传感器线圈阵列和/或感测场,使得该感测场可以扫描感测区域,并且被配置为基于该感测阵列输出来检测该感测区域中至少一个外来物体的存在。该传感器线圈阵列和/或感测场是可移动的,使得该感测场可以：a)定位在该感测区域中,使得该感测场不与该至少一个外来物体重叠,以及b)定位在该感测区域中,使得该感测场与该至少一个外来物体重叠。(A charging unit for wireless power transfer is described herein. The charging unit includes at least one coil for inductive power transfer, a sensor coil array having a sensing field for sensing the presence of at least one foreign object, and a controller. The controller is configured to move the sensor coil array and/or sensing field such that the sensing field can scan a sensing region, and to detect the presence of at least one foreign object in the sensing region based on the sensing array output. The sensor coil array and/or the sensing field are movable such that the sensing field can: a) positioned in the sensing region such that the sensing field does not overlap with the at least one foreign object, and b) positioned in the sensing region such that the sensing field overlaps with the at least one foreign object.)

1. A charging unit for wireless power transfer, comprising:

at least one coil for inductive power transfer,

a sensor coil array having a sensing field for sensing the presence of at least one foreign object;

and

a controller configured to:

moving the sensor coil array and/or the sensing field such that the sensing field can scan the sensing area, and

detecting a presence of the at least one foreign object in the sensing region based on the sensing array output,

wherein the sensor coil array and/or the sensing field are movable such that the sensing field can:

a) positioned in the sensing region such that the sensing field does not overlap with the at least one foreign object, an

b) Positioned in the sensing region such that the sensing field overlaps with the at least one foreign object.

2. The charging unit of claim 1, wherein the charging unit is configured to wirelessly charge an electric vehicle via inductive power transfer.

3. The charging unit of claim 1 or 2, further comprising an arm, wherein the sensor coil array is arranged on the arm, and the controller can control movement of the arm to position the sensing field in the sensing region.

4. The charging unit of claim 3, wherein the arm is a rotatable arm and the controller can rotate the arm to position the sensing field.

5. The charging unit of claim 3, wherein the arm is a slidable arm and the controller is capable of sliding the arm to position the sensing field.

6. The charging unit of any one of the preceding claims, wherein the charging unit has an operating region and the sensing region overlaps the operating region.

7. The charging unit according to any of the preceding claims, wherein the sensor coil array and/or sensing field is smaller than the operating area.

8. The charging unit of any one of the preceding claims, further comprising one or more additional sensor arrays for sensing the presence of the at least one foreign object.

9. The charging unit of claim 8, wherein each additional sensor array is disposed on a respective additional arm.

10. The charging unit of any one of the preceding claims, wherein the charging unit comprises an electromagnetic shielding material for shielding the sensor coil array from electromagnetic interference.

11. The charging unit of any one of the preceding claims, wherein the charging unit is for wirelessly charging one or more of:

electric system

Batteries

Scooter

Electric bicycle

Robot

Other electronic devices

12. A charging unit for wirelessly charging an electric vehicle by inductive power transfer, comprising:

at least one coil for inductive power transfer,

a sensor coil array having a sensing field for sensing the presence of a foreign object;

and

a controller configured to:

moving the sensor coil array and/or the sensing field such that the sensing field can scan the sensing area, and

detecting a presence of a foreign object in the sensing region based on the sensing array output,

wherein the sensor coil array and/or the sensing field are movable such that the sensing field can:

a) positioned in the sensing region such that the sensing field does not overlap with foreign objects, an

b) Positioned in the sensing region such that the sensing field overlaps the foreign object.

13. A sensing unit of a charging unit for wireless power transfer, comprising:

A sensor coil array having a sensing field for sensing the presence of at least one foreign object;

and

a controller or in communication with a controller, the controller configured to:

moving the sensor coil array and/or the sensing field such that the sensing field can scan the sensing area, and

detecting a presence of the at least one foreign object in the sensing region based on the sensing array output,

wherein the sensor coil array and/or the sensing field are movable such that the sensing field can:

a) positioned in the sensing region such that the sensing field does not overlap with the at least one foreign object, an

Positioned in the sensing region such that the sensing field overlaps with the at least one foreign object.

14. The sensing unit according to claim 13, wherein the charging unit is for wirelessly charging an electric vehicle by inductive power transfer.

15. The sensing unit according to claim 13 or 14, further comprising one or more sensor arrays for sensing the presence of the at least one foreign object.

16. The sensing unit of any one of the claims, wherein the charging unit is for wirelessly charging one or more of:

Electric system

Batteries

Scooter

Electric bicycle

Robot

Other electronic devices

17. A wireless power transfer system comprising a charging unit and/or a sensing unit according to any of the preceding claims.

18. A power system for wireless power transfer for charging and/or powering a system or device in real time, comprising:

at least one coil for inductive power transfer,

a sensor coil array having a sensing field for sensing the presence of at least one foreign object;

and

a controller configured to:

moving the sensor coil array and/or the sensing field such that the sensing field can scan the sensing area, and

detecting a presence of the at least one foreign object in the sensing region based on the sensing array output,

wherein the sensor coil array and/or the sensing field are movable such that the sensing field can:

a) positioned in the sensing region such that the sensing field does not overlap with the at least one foreign object, an

b) Positioned in the sensing region such that the sensing field overlaps with the at least one foreign object.

Technical Field

The present invention relates to a wireless power transfer system (charging or real-time power system) and an apparatus for detecting foreign objects thereon.

Background

Fig. 1 shows a prior art wireless power transfer charging system 10 for charging an electric vehicle 11. The charging system comprises a central charging unit 12 having a power supply 9 and a controller 8 for controlling the supply of power to the electric vehicle 11, and further comprises a wireless charging unit 13 which inductively transfers power 15 to the electric vehicle 11. The central charging unit 12 is electrically coupled 16 with the wireless charging unit 13. The wireless charging unit 13 may take the form of a wireless charging pad 40 that includes one or more induction coils 14 for transferring power to the electric vehicle 11.

In operation, the central charging unit 12 induces an alternating current into the induction coil 14, which creates a varying electromagnetic field/flux in and around the induction coil 14. The electric vehicle has a receiver 17, and the receiver 17 receives power inductively transmitted from the wireless charging unit 13. The receiver 17 is electrically coupled to a rechargeable battery 18. If the receiver 17 of the electric vehicle 11 is in the vicinity of the wireless charging pad 13, the varying electromagnetic field/flux induces an alternating current in the induction coil of the receiver 17, thereby generating a wireless transmission of power 15 to the electric vehicle 11.

If a foreign object is also located in the vicinity of the wireless charging pad 13, the varying electromagnetic field will induce eddy currents in the foreign object. If the resistance of the foreign object is low, the foreign object will start to heat up and continued exposure to electromagnetic flux increases the risk that the foreign object becomes a heating and/or fire hazard.

Disclosure of Invention

It is an object of the present invention to provide object sensing in wireless power transfer.

The present embodiment provides a foreign object detection system for a wireless power transfer charging system 10 such that remedial action can be taken if a foreign object is on the wireless charging pad 13 or sufficiently close to the wireless charging pad 13. For example, the wireless charging pad 13 may be powered off and/or turned off to prevent foreign objects from being a safety hazard.

In one aspect, the invention may be said to consist in a charging unit for wireless power transfer, the charging unit comprising: at least one coil for inductive power transfer, a sensor coil array having a sensing field for sensing the presence of at least one foreign object, and

a controller configured to: moving the sensor coil array and/or sensing field such that the sensing field can scan a sensing region, and detecting the presence of at least one foreign object in the sensing region based on the sensing array output, wherein the sensor coil array and/or sensing field are movable such that the sensing field can:

a) positioned in the sensing region such that the sensing field does not overlap with the at least one foreign object, and b) positioned in the sensing region such that the sensing field overlaps with the at least one foreign object.

Optionally, the charging unit is configured to wirelessly charge the electric vehicle by inductive power transfer.

Optionally, the charging unit further comprises an arm, wherein the sensor coil array is arranged on the arm, the controller being capable of controlling the arm to move to position the sensing field in the sensing region.

Optionally, the arm is a rotatable arm and the controller is capable of rotating the arm to position the sensing field.

Optionally, the arm is a slidable arm and the controller is capable of sliding the arm to position the sensing region.

Optionally, the charging unit has an operating region, and the sensing region overlaps the operating region.

Optionally, the sensor coil array and/or the sensing field is smaller than the operating area.

Optionally, the charging unit further comprises one or more additional sensor arrays for sensing the presence of the at least one foreign object.

Optionally, each additional sensor array is arranged on a respective additional arm.

Optionally, the charging unit comprises an electromagnetic shielding material for shielding the sensor coil array from electromagnetic interference.

Optionally, the charging unit is configured to wirelessly charge one or more of:

electric system

Batteries

Scooter

Electric bicycle

Robot

Other electronic devices

In another aspect, the invention may be said to consist in a charging unit for wireless charging of an electric vehicle by inductive power transfer, the charging unit comprising: at least one coil for inductive power transfer, a sensor coil array having a sensing field for sensing the presence of a foreign object, and a controller configured to: moving a sensor coil array and/or a sensing field such that the sensing field can scan a sensing region and detect the presence of a foreign object in the sensing region based on the sensing array output, wherein the sensor coil array and/or the sensing field are movable such that the sensing field can: a) positioned in the sensing region such that the sensing field does not overlap with the foreign object, and b) positioned in the sensing region such that the sensing field overlaps with the foreign object.

In another aspect, the invention may be said to reside in a sensing unit comprising a charging unit for wireless power transfer, the charging unit comprising: a sensor coil array having a sensing field for sensing the presence of at least one foreign object, and a controller or in communication with the controller, the controller configured to: moving the sensor coil array and/or the sensing field such that the sensing field is able to scan the sensing region and detecting the presence of at least one foreign object in the sensing region based on the sensing array output, wherein the sensor coil array and/or the sensing field are movable such that the sensing field can:

a) the method further includes positioning in the sensing region such that the sensing field does not overlap with the at least one foreign object, and positioning in the sensing region such that the sensing field overlaps with the at least one foreign object.

Optionally, the charging unit is configured to wirelessly charge the electric vehicle by inductive power transfer.

Optionally, the charging unit further comprises one or more sensor arrays for sensing the presence of the at least one foreign object.

Optionally, the charging unit is configured to wirelessly charge one or more of:

Electric system

Batteries

Scooter

Electric bicycle

Robot

Other electronic devices

In another aspect, the invention may be said to comprise a wireless power transfer system comprising a charging unit and/or a sensing unit according to any of the preceding aspects of the invention.

In another aspect, the invention may be said to reside in a power system including wireless power transfer for charging and/or real-time powering of a system or device, comprising: at least one coil for inductive power transfer, a sensor coil array having a sensing field for sensing the presence of at least one foreign object, and a controller configured to: moving the sensor coil array and/or the sensing field such that the sensing field can scan the sensing region; and detecting the presence of the at least one foreign object in the sensing region based on the sensing array output, wherein the sensor coil array and/or sensing field are moveable such that the sensing field can: a) positioned in the sensing region such that the sensing field does not overlap with the at least one foreign object, and b) positioned in the sensing region such that the sensing field overlaps with the at least one foreign object.

The term "comprising" as used in the present specification and claims means "consisting at least in part of …". When interpreting each expression in this specification and claims that includes the term "comprising," there can also be features other than, or prefaced by, that term. Related terms such as "comprise" and "comprises" are to be interpreted in the same way.

A numerical range disclosed herein (e.g., 1 to 10) also includes reference to all rational numbers within that range (e.g., 1, 1.1, 2, 3, 3.9, 4, 5, 6, 6.5, 7, 8, 9, and 10) and any range of rational numbers within that range (e.g., 2 to 8, 1.5 to 5.5, and 3.1 to 4.7).

The invention may also be said broadly to consist in the parts, elements and features referred to or indicated in the specification of the application, individually or collectively, and any or all combinations of any two or more of said parts, elements or features, and where specific integers are mentioned herein which have known equivalents in the art to which the invention relates, such known equivalents are deemed to be incorporated herein as if individually set forth.

Drawings

Preferred embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which:

fig. 1 is an overview of a prior art wireless power transfer charging system.

Fig. 2 is a general overview of a wireless power transfer charging system in accordance with the described embodiments.

Fig. 3 is a block diagram overview of a wireless charging unit according to the described embodiment.

FIG. 4 is a block diagram overview of a sensing unit according to the described embodiment.

FIG. 5 is a plan view of one embodiment of a sensing unit.

Fig. 6 is a line graph illustrating an example of how one embodiment of the sensing unit senses and detects a foreign object.

FIG. 7 is a plan view of another embodiment of a sensing unit.

Fig. 8 is a line drawing illustrating an example of how another embodiment of the sensing unit senses and detects a foreign object.

FIG. 9 is a plan view of another embodiment of a sensing cell.

FIG. 10 is a plan view of another embodiment of a sensing cell.

Fig. 11 is a plan view of a prior art foreign object detection system.

Fig. 12 is a line drawing showing the reason why it is difficult to detect a foreign object with the foreign object detection system of the related art.

Detailed Description

Overview of the described embodiments

Fig. 2 shows a wireless power transfer charging system 10 for charging an electric vehicle 11, which is configured to enable detection of foreign objects in an operating area of a wireless charging unit 13.

The wireless power transfer charging system 10 includes a central charging unit 12 for controlling the supply of power to the electric vehicle 11, and also includes a wireless charging unit 13 that inductively transfers power 15 to the electric vehicle 11. The charging unit 13 is electrically coupled 16 with the central charging unit 12. The wireless charging unit 13 may take the form of a wireless charging pad comprising one or more induction coils 14 for transferring power 15 to the electric vehicles 17, 18.

In operation, the central charging unit 12 induces an alternating current into the induction coil 14, which creates a varying electromagnetic field/flux in and around the induction coil 14. The electric vehicle 11 has a receiver 17, which receiver 17 receives power inductively transmitted 15 from the wireless charging unit 13. The receiver 17 is electrically coupled to a rechargeable battery 18. If the receiver 17 of the electric vehicle 11 is in the vicinity of the wireless charging pad 13, the varying electromagnetic field/flux induces an alternating current in the induction coil of the receiver 17, thereby generating a wireless transmission of power 15 to the electric vehicle 13. The foreign object sensing unit 20 is provided to detect any foreign object in the operation region of the charging unit 13.

In summary, the described embodiments provide a sensing unit 20, a wireless power transfer charging unit 13 with a sensing unit 20 and/or a wireless power transfer charging system 10 with a charging unit 13, whereby the sensing unit 20 can sense and detect foreign objects (on or near the charging unit) that may present a hazard as previously stated.

Embodiments disclosed herein are described in terms of sensing and detecting a single foreign object as opposed to two or more foreign objects. This is to provide a simplified explanation as to how foreign objects may be detected and sensed by the embodiments described herein. One skilled in the art will appreciate that the described embodiments are capable of sensing and detecting a single foreign object, and are also capable of sensing and detecting two or more foreign objects. This is because the technique for sensing and detecting a single foreign object can also be used to detect two or more foreign objects.

The embodiments of the wireless power transfer charging system 10, the sensing unit 20, and the wireless power charging unit 13 described herein are all described in the context of wirelessly charging the electric vehicle 11. However, those skilled in the art will appreciate that the described embodiments may also be applicable to systems that power an electrical system in real time or to charge a battery. Furthermore, the described embodiments may be applicable to charging scooters, electric bicycles, robots, and other similar electronic devices.

Various embodiments of the wireless charging unit 13 that can sense foreign objects are described. In summary, referring to fig. 3, embodiments provide a sensing coil array 34 that can scan a sensing region 31 and a controller 32 that can detect a foreign object 33 in the sensing region 31. Upon detection, appropriate action may be taken to prevent danger, such as turning off the wireless charging unit 13. Typically, the sensing coil array will be in the housing of the charging unit 13.

The controller 32 is able to detect the foreign object 33. Further, the controller 32 may be used to operate any actuator for moving the sensing array 34, and the controller 32 may be used to power the sensing coil array 34 (including the sensing coils themselves). The controller 32 may refer to one or more controllers that may be placed anywhere in the wireless charging unit 13.

Referring to fig. 4, various general features of the wireless charging unit 13 and the sensing unit 20 are shown in general diagrammatic form. The various geometric areas are shown for illustrative purposes only and may not correspond to the actual geometric areas of the charging unit according to the described embodiments.

The charging unit 13 takes the form of a charging mat 40 having a housing covering an area. In this case, the pad 40 and the housing are circular, but they may take other shapes, such as square, rectangular, or other shapes. The charging pad 40 comprises a wireless power transmitting charging coil ("power coil") 14-in this case one, although the actual number will depend on the charging unit 13. The coil 14 has an operating region 41, which is the region where the electromagnetic field of the power coils 14 can operate to provide power transmission 15 to the electric vehicle 11. Foreign objects 42 falling within the operating area 41 are at risk of creating an overheating hazard as they receive power for the vehicle 11. Accordingly, embodiments herein are directed to detecting such foreign objects 42 within the operational area 41. The geometry of the operating region 41 may or may not completely coincide with the geometry of the charging pad region 40. Depending on the range of the wireless power transfer 15, the operating region 41 may coincide, partially coincide, be larger, or be smaller than the charging pad area 40. Typically, the operating area 41 and the charging pad area 40 will be closely aligned. The term "overlap" with respect to the operating region 41 and the charging pad 40 shall mean that the operating region 41 at least partially coincides with the charging pad 40 (whether it is larger or smaller) and may be completely coincident with (i.e. of the same size and substantially completely aligned with) the charging pad 40, or it may even be larger than the charging pad 40. The term "overlying" means that the region is at least aligned with or even larger than another region.

The charging unit 13 has a sensing unit (generally depicted as 43). The sensing unit 43 may be integrated with the charging unit 13 or a separate device, and may be either renewable or incorporated at the time of manufacture. The sensing unit 43 includes a sensor arm 44 and a sensor coil array 45 arranged on the sensor arm 44. Sensor coil array 45 is shown as a single array of multiple sensing coils, e.g., 45a, but this is merely exemplary and other geometries and numbers of sensing coils are possible. The sensor coil array 45 has an electromagnetic sensing field ("sensing field") 46, which is a geometric area over which the sensor coil array 45 can manipulate/sense the foreign object 42 to a suitable measurement level.

The sensor coil array 45 (and hence the sensing field 46) is smaller than the operating region 41, for reasons of advantage which will be explained later. As a result, the sensing field 46 does not cover/overlap and the foreign object 42 cannot be sensed over the entire operating area (when stationary). Thus, the sensing unit 46 has a controller 32 and an actuator 47, the actuator 47 under the control of the controller 32 may operate the sensor coil array 45 such that the sensing field 46 may scan a larger area. This may be by moving the sensor arm 44 and/or the sensor coil array 45 such that the sensing field 46 scans a larger area. The area scanned by the sensing field 46 is the sensing area 48. The sensing region 48 is a region where the foreign object sensing unit 20 can sense and detect the foreign object 42. Preferably, the sensing area 48 is at least the same size as and completely covers the operating area 41 of the charging unit 13. The sensing region area 48 may be larger than the operating region area 41. However, it may not be absolutely necessary that the sensing region 48 be the same size as the operating region 41 or larger than the operating region 41, and a sensing region 48 that covers only a portion of the operating region 41 may still be useful. Even if the sensing region 48 does not completely coincide with the operating region 41, e.g. it overlaps but does not completely cover it, some benefits may still be obtained. However, any operating region 41 not scanned is in danger of hiding foreign objects 42 that would not be detected and may pose a heating hazard. The term "overlap" with respect to the operative region 41 and the sensing region 48 shall mean that the sensing region 48 at least partially coincides with the operative region 41 (whether it is larger or smaller), and may be completely coincident with the operative region 41 (i.e. of the same size and substantially completely aligned), or it may even be larger than the operative region 41. The term "overlying" means that the region is at least aligned with or even larger than another region. As shown in fig. 4, the sensing region 48 is slightly larger than the operating region 41. The sensing field 46 may not conform to the geometry of the sensor arm 44. Typically, it may be larger than the sensor arm 44, although this is not required, and it may have other relationships with the sensor arm 44, such as being coincident with the sensor arm 44, partially or completely overlapping the sensor arm 44, and/or being smaller than the sensor arm 44.

As shown in fig. 4, arm 44 may be moved by actuator 47 such that sensing coil array 45 rotates to scan (sweep out) sensing region 48. In this case, the arm 44 is rotated to sweep out the circular sensing area 48. It can be seen that the actual area swept by arm 44 (arm movement area 49) is smaller than sensing area 48, since sensing field 46 is slightly longer than arm 44, so it sweeps a larger radius. Having a rotating sensor arm 44 is only one option for moving the sensing field 46, and other options are possible, creating differently shaped sensing regions 48, some of which will be described below.

The geometry of the sensing field 46 and the sensing region 48 is arranged with respect to the operating region 41 such that at least one position of the sensing field 46 is present such that the sensing field 46 does not overlap (meaning that it does not partially or completely coincide) with the foreign object 42 in the operating region 41, and at least one position of the sensing region is present such that it does not overlap (meaning that it at least partially or completely coincides) with the foreign object 42 in the operating region 41. In practice, there are typically multiple locations for both, but as long as there is at least one location for each location, the sensing field 46, sensing region 48, and movement can take on a variety of different geometries and motions.

The shielding helps to attenuate the electromagnetic field emitted from the power coil 14 so that electromagnetic interference with signals induced in the sensing coils 45a of the sensing array 45 is mitigated. The arm of this embodiment can incorporate more shielding material because the sense bar 44 occupies a smaller area relative to the sensing region 48.

It will be appreciated that the boundaries of the regions relating to the electromagnetic field shown in figure 4 may not be the actual shape of these regions. These shapes are shown for exemplary purposes only. It should also be understood that the boundaries of the illustrated regions will not actually be "hard" boundaries, i.e., the depicted electromagnetic field will not necessarily become zero outside of immediately adjacent boundaries. Instead, the electromagnetic field decays as a function of distance from the field source. The boundaries of the depicted regions are merely indicative and show locations where the active field can be considered to have ended. Those skilled in the art will understand this and the boundaries should not be viewed as limiting in such a way that they limit the scope of the invention in a manner that is contrary to the concepts described herein.

The embodiments described herein have the following advantages over prior art sensing arrays.

The sensor coil array 45 does not need to be the same size as the operating field 41 to effectively detect foreign objects 42 in the operating field. But a smaller sensor coil array 45 may be used. A small footprint of the sensor coil array 45 may be used. This saves the cost of the coil and accompanying control and sensing electronics.

The coils of the prior art sensing array are preferably shielded so that the field of the wireless power transfer coil 14 does not interfere with the sensing coil 45. However, if the prior art coil array is of a considerable size, there is a large shielded area, which will prevent or attenuate the power transferred to the vehicle 11. In contrast, the smaller sensor coil arrays 45 of the embodiments described herein require a smaller shielding area, so they do not shield all or most of the power coils 14, and therefore do not attenuate power transfer to a great extent. Because the sensor coil array 45 requires a smaller shielding area, a higher level (e.g., thickness) of shielding around the sensor coil array 45 can be provided without impeding the operation of the wireless power transfer coil 14. The additional shielding reduces electromagnetic interference from the wireless power transfer coil 14, which improves the quality of the signal sensed by the sensor coil array 45. This improves the accuracy and/or precision of the sensor coil array 15 measurements. In addition, the additional shield thickness allows the controller 32 to be placed closer to the sensor coil array 45. Physically placing the controller 32 closer to the sensor coil array 45 also improves the accuracy and/or precision of the measurements of the sensor coil array 45.

Having a reference helps to distinguish whether a foreign object 42 is present when detecting the foreign object 42 using the sensor coil array. For example, as shown in fig. 11, with a prior art sensor coil array 15 covering most or all of the operating area, it is possible to always sense a foreign object 42 to some extent. Thus, it is difficult to determine the difference from when the object 42 is present to when it is not present, see, for example, fig. 12. In contrast, the present embodiment has a situation where the size of the sensing field 46 is such that at times only the object 42 is sensed, while at other times it is not, so that the two readings can distinguish whether the object 42 is there or not.

Specific exemplary embodiments will now be described. These are not limiting and are merely examples. Various other embodiments may be devised by those skilled in the art that still meet aspects of the invention.

Specific embodiments according to the present invention will now be discussed.

1. First embodiment

A first embodiment will now be discussed with reference to fig. 5 and 6.

The charging unit 13 forming part of the system of fig. 2 may be as shown in fig. 5 and 6. Various features of this embodiment will be renumbered with respect to previous figures, but they still relate to the same aspects as the context specifies. The charging unit 13 of this embodiment comprises a circular pad 50, the circular pad 50 comprising a housing and at least one wireless power transfer coil 57. The charging unit 13 has a rotatable sensor arm ("rotatable arm") 54 that is disposed over a pad 50 on a rotatable actuator (e.g., an electric motor). Preferably, the rotatable arm is in the charging unit housing, although this is not essential. The rotatable actuator is controlled to rotate by a controller (e.g. 32 in fig. 3) arranged in the charging unit 13 or elsewhere in the system. The sensor coil array 55 is arranged on the rotatable arm 54. The arm is sized to carry a sensor coil array 55. The sensor coil 55 may be any suitable coil used in the art. The rotatable arm 54 and/or sensor coil 55 may be shielded to reduce interference from the charging coil 14.

The following regions are also shown:

a circular charging pad housing 50.

A circular operating area 51, which is an area over which the wireless power transfer coil 14 can transfer power. This is typically a similar area as the charging pad 50, i.e. they overlap.

A rotatable arm 54 having a sensor coil 55 covering an elongated rectangular area.

A sensing field 53, which is the area where the sensor coil 55 can sense the object 52 when the rotatable arm 54/sensor coil array 55 is in a particular position.

Circular sensing area 58, is the area that sensing field 53 is scanned or swept by the rotatable movement of arm 54.

The area covered by the sensor coil array 55 and the rotatable arm 54 and the sensing field 53 is a small part of the entire operating region 51, which is advantageous for the reasons mentioned above. In particular, sensing field 53 and sensing region geometry 58 are arranged relative to operating region 51 such that there is at least one location of sensing field 53 such that it does not overlap with foreign object 52 in the operating region (see, e.g., location a, location C, and location D), and at least one location of sensing field 53 such that it overlaps with foreign object 52 in the operating region (see location B). In practice, there are many such locations for each. There is a vertical gap between the rotatable arm 54 and the charging unit pad 50 such that when the arm 54 rotates, it will pass over any foreign object 52 on the pad 50 or otherwise pass in the operating zone 51.

In use, the rotatable arm 54 is rotated by the actuator under the control of the controller 32 such that the sensor coil array 55 scans/sweeps out of the circular arm movement region 59 and the sensing field 53 scans/sweeps out of the sensing region 58, thereby allowing the sensor coil array 55 to sense any foreign objects 52 located in the sensing region 58/operational region 51. Four positions (positions A, B, C and D) of the rotatable arm 54 are shown, but it should be understood that the arm 54 will rotate through a continuous range of different positions. It can be seen that as arm 54 rotates, for most of the position, sensing field 53 does not cover foreign object 52, but for a small portion of the scan (for a smaller range of positions), arm 54 covers (and therefore sensing field 53 covers) foreign object 52.

When the rotating arm 54/sensor coil array 55 is positioned such that the sensing field 53 does not overlap (e.g., does not cover or is too far to sense) any foreign object 52, the sensor coil array 55 will not sense the object 52. See, e.g., positions a and C. The controller 32 receives an output from the sensor coil array of a substantially zero signal 60 (see fig. 6) or a signal indicating that there is no object. Once the sensor coil array 55 is in one of the positions (e.g., position B) where the sensing field 53 overlaps (e.g., covers or is proximate to sensing) the foreign object 52, the controller 32 receives an output from the sensor coil array 55 as a positive signal 61a, B (see fig. 6) from which the controller detects the foreign object 52. Controller 32 may use the relative output from when sensing field 53 does not sense or overlap object 52 to when it overlaps/senses object 52 to help distinguish between these two events.

For example, at position a, sensing bar 54 is oriented in a "north-south" direction, and foreign object 52 does not overlap sensing field 53 (and is too far from sensing field 53). Foreign object 52 is too far from sensing field 53 to induce an electrical signal into any sensing coil 55 located along arm 54. Since no electrical signal is induced in any of the sensing coils 55, the controller 32 receives a ("low") zero reading 60 from the sensor coil array 55. The rotatable arm 54 starts to rotate clockwise towards position B. In position B, the arm 54 is oriented in the "northeast-southwest direction". In this position, the sensor coil array 55 overlaps the foreign object 52. As a result of the electrical signal induced in the at least one sensing coil 55, the controller 32 receives a ("high") non-zero reading 61. The arm 54 continues to rotate clockwise toward position C. In position C, the sensor coil array 55 is oriented in the "west-east" direction. In this position, the foreign object 52 is too far from the sensor coil array 55 to induce an electrical signal into any sensing coils 55 located along the rotatable arm 54. Since no electrical signal is induced in any of the sensing coils 55, the controller 32 receives a ("low") zero reading 60 from the sensor coil array 55. Arm 54 continues to rotate clockwise toward position D. In position D, the sensing lever 54 is oriented in the "northwest-southeast" direction. In this position, the foreign object 52 is too far from the sensor coil array 55/sensing field 53 to induce an electrical signal into any of the sensing coils 55 located along the rotatable shaft 54. Since no electrical signal is induced in any of the sensing coils 55, the controller receives a ("low") zero reading 60 from the sensor coil array. Arm 54 continues to rotate clockwise toward position a, and may continue to rotate clockwise.

By rotating the sensing lever 54 again from position a to position D and position a, the controller 32 receives a ("low") zero reading 60 and a ("high") non-zero reading 61. The controller can reference ("high") non-zero readings 61 against ("low") zero 60 readings to correctly determine the presence of foreign objects 52 within the sensing region 58. The controller 32 then de-energizes the induction coil 57 of the charging pad to prevent induction heating of the foreign object 52. Thus, foreign object 52 is no longer an induction heating hazard.

Once detection occurs, the controller 32 may communicate with the central charging unit 12 to take appropriate action, such as shutting down power transmission.

Those skilled in the art will appreciate that instead of continuously moving the rod 54 in a continuous clockwise direction, the rod 54 may be rotated in other ways. For example, the rotatable lever 54 may move in alternating "stop" and "start" movements. In another example, the rotatable lever 54 may rotate in a counterclockwise direction. In another example, the rotatable lever 54 may be alternately moved between a clockwise direction and a counterclockwise direction.

The disclosed embodiments suggest sensing and detecting different voltage signals (i.e., a non-zero reading when a foreign object is present, and a zero reading when no foreign object is present) to determine whether a foreign object 52 is present in the sensing region 53. Those skilled in the art will appreciate that the controller 32 may be configured to alternatively measure different parameters to determine whether a foreign object 52 is present in the sensing region 53. That is, instead of using relative voltage levels, the controller may instead measure, for example, frequency, phase shift, or some other parameter.

2. Second embodiment

A second embodiment will now be discussed with reference to fig. 7 and 8.

The charging unit 13 forming part of the system of fig. 2 may be as shown in fig. 7 and 8. Various features of this embodiment will be renumbered with respect to previous figures, but they still relate to the same aspects as the context specifies. The charging unit 13 of this embodiment includes a rectangular pad 70, and the rectangular pad 70 includes a case and at least one power coil 77 (three coils in this case). The charging unit 13 has a slidable sensor arm ("slidable arm") 74 that is disposed over a pad 70 on a sliding actuator (e.g., a linear motor). Preferably, the slidable arm is in the charging unit housing, although this is not essential. The actuator is controlled to slide the arm 74 by means of a controller 32 arranged in the charging unit 13 or elsewhere in the system. A sensor coil array 75 is arranged on the slidable arm 74. The arms 74 are rectangular and span a width slightly less than the width of the sensing region 78. These sensing coils 75 are coupled to control electronics. The arm 74 is sized to carry a sensor coil array 75. The sensor coil 75 may be any suitable coil used in the art. The slidable arm 74 and/or the sensor coil 75 can be shielded to reduce interference from the charging coil 77.

The following regions are also shown:

a rectangular charging pad 70 housing.

The operation area 71 is an area over which the wireless power transmission coil can transmit power. This generally has a similar area as the charging pad 70. This may be a quasi-elliptical shape in nature, or some other shape that reflects the total electromagnetic field of the power coil 77. Regardless, the operating region 71 will most likely have a similarly sized dimension and cover or extend beyond the rectangular pad area 70. That is, preferably, the sensing region 78 coincides with the operation region 71. However, some useful gain may be obtained even if there is no perfect coincidence.

A slidable arm 74 having a sensor coil 75 covering an elongated rectangular area.

Sensor field 73, which is the area where sensor coil 77 can sense object 72 when rotatable arm 74/sensor coil array 75 is in a particular position.

A generally rectangular sensing region 78, which is the region that the sensing field 73 scans or sweeps through by the sliding movement of the arm 74.

The area covered by the sensor coil array 75 and the slidable arm 74 and the sensing field 73 is a small part of the entire operating region 71, which is advantageous for the reasons mentioned above. In particular, sensing field 73 and sensing region geometry 78 are arranged with respect to operating region 71 such that there is at least one position of sensing region 73 such that it does not overlap with foreign object 72 in operating region 71 (see positions a and C), and at least one position of sensing field 73 such that it overlaps with foreign object 72 in operating region 71 (see position B). In practice, there are many such locations for each. There is a gap between the slidable arm 74 and the charging unit pad 70 such that when the arm 74 moves, it will pass over any foreign object 72 on the pad 70 or otherwise pass in the operating zone 71.

In use, the arm 74 is manipulated by an actuator which can move the rod across the sensing region, for example position a through position B to position C. The actuator may be any suitable mechanism, such as an electromagnetic rail. The actuator is controlled by a controller 32 in the charging unit, in the controller unit 32, or elsewhere in the system. The slidable bar 74 is moved laterally by the actuator under the control of the controller 32 such that the sensor coil array 75 scans/sweeps across the rectangular moving area 79 and the sensing field 73 scans/sweeps out of the quasi-rectangular sensing area 78, allowing the sensor coil array 55 to sense any foreign objects 72 located in the sensing area 78/operating area 71. The three positions of the slidable arm 74 are shown as A, B, C, but it should be understood that the arm 74 will move through a continuous range of different positions. It can be seen that as the arm 74 moves, the sensing field 73 does not cover the foreign object 72 for most of the position, but for a small portion of the scan (for a smaller range of positions) the arm 74 covers (and therefore the sensing field 73 covers) the foreign object 72.

Arm 74 moves laterally from one end of sensing region 78 to the opposite end, allowing region and sensing field 73 to scan sensing region 78 to sense any foreign objects 72 located in operating region 71. When the arm 74/sensor coil array 75 is positioned such that the sensor field 73 does not overlap (e.g., does not cover or is too far to sense) the foreign object 72, the sensor coil array 75 will not sense the object 72. See, e.g., positions a and C. The controller 32 receives an output from the sensor coil array 75 of a substantially zero signal 80 (see fig. 8) or a signal indicating that there is no object. Once the sensor coil array 75 is in one of the positions (e.g., position B) where the sensing field 73 overlaps (e.g., covers or is proximate to sensing) the foreign object 72, the controller 32 receives an output from the sensor coil array 75 as a positive signal 81 from which positive signal 81 the controller 32 detects the foreign object 72. The controller 32 may use the relative output from when the sensing field 73 does not sense or overlap the object 72 to when it overlaps/senses the object 72 to help distinguish between these two events.

For example, referring to fig. 7 and 8, at position a, arm 74 is at the edge of sensing region 78, and foreign object 72 is too far from arm 74 to induce an electrical signal into any of sensing coils 75 located along arm 74. Since no electrical signal is induced in any of the sensing coils 75, the controller 32 receives a "low" zero reading 80 from the arm. The arm 74 starts moving further to the right towards position B. In position B, the sense lever 74 is located in the middle of the sensing region 78. In this position, the sensing bar 74 overlaps the foreign object 72, and the foreign object 72 is close enough to induce an electrical signal into at least one sensing coil 75 positioned along the arm 74. The controller 32 receives a ("high") 81 non-zero reading due to the electrical signal induced in the at least one sensing coil 75. The arm 74 continues to move further to the right towards position C. At position C, arm 74 is at the edge of sensing region 78, and similar to position a, foreign object 72 is too far from arm 74/sensing field 73, and thus controller 32 receives a ("low") 80 zero reading from arm 74. From position C, the direction of travel of the sense lever 74 may be reversed, thereby causing the sense lever 74 to begin returning toward position a.

By moving the sense lever 74 from position a to position C, the controller 32 receives a ("low") 80 zero reading and a ("high") 81 non-zero reading. The controller can reference ("high") non-zero readings 81 against ("low") zero readings 80 to correctly determine the presence of foreign objects 72 within the sensing region 78. The controller 32 then de-energizes the induction coil 77 of the charging pad to prevent induction heating of the foreign object 72. Thus, the foreign object 72 is no longer an induction heating hazard.

Once detection occurs, the controller 32 may communicate with the system controller to take appropriate action, such as shutting down power transmission. Those skilled in the art will appreciate that the rod 74 may be rotated in other ways instead of continuously moving the rod 74 in a continuous motion. For example, the slidable rod 74 may move in alternating "stop" and "start" movements.

The disclosed embodiments suggest sensing and detecting different voltage signals (i.e., a non-zero reading when a foreign object is present, and a zero reading when no foreign object is present) to determine whether a foreign object 72 is present in the sensing region 73. Those skilled in the art will appreciate that the controller 32 may be configured to alternatively measure different parameters to determine whether a foreign object 72 is present in the sensing region 73. That is, instead of using relative voltage levels, the controller may instead measure, for example, frequency, phase shift, or some other parameter.

3. Variations in

It will be appreciated that many variations are possible with respect to the above embodiments. For example, no single coil array is required for the sensor coil array-there may be two, three or even more coil arrays, each array comprising one or more coil columns. Further, each coil array may each be arranged on its own arm-i.e., some embodiments may have multiple sense arms, each with its own coil array. Each sensing arm may move independently or together. Further, the number of coils may be any suitable number. The consideration of the number of coils is of course the sensitivity, but also a compromise between this consideration and optimizing the minimum size of the sensor coil array (and hence the arm), so that the cost can be kept at a desired level, i.e. the shielding can be kept at a desired level, and the array can also always be placed in a position where it does not detect a foreign object and in another position where it does not detect a foreign object, so that the reference between the two readings can improve the detection.

Referring to fig. 9, in a slidable arm 94 arrangement where the operating zone 91 and sensing region 98 are rectangular, typically the largest dimension of the sensor coil array 95 will produce a sensing field 93 having an area slightly less than half the area of the sensing region 98 so that at least non-sensing and sensing positions of foreign objects may be present. In practice, it is desirable to have a sensor coil array 95 that produces a much smaller sensing field 93 than this. For example, the area of sensing field 93 may be less than 50% of the area of sensing region 98, or less than 40% of the area of sensing region 98, or less than 30% of the area of sensing region 98, or less than 25% of the area of sensing region 98, or less than 10% of the area of sensing region 98.

Referring to fig. 10, in a rotary arm arrangement 104 where the operating zone 101 and the sensing area are circular, the sensor coil array 104 may theoretically be a significant part of the entire circle to generate the sensing field 103, the sensing field 103 being a significant part of the entire circle with a small area, the sensing field 103 not being present. This means that when a rotation of the sensor coil array 105 occurs, there is still a small area of the sensing region 108 where no sensing occurs. In practice, however, it is more desirable to have a sensor coil array 105 that produces a sensing field 103 much smaller than this, more similar to that described in the above embodiments.

The above embodiments relate to a charging unit. Wireless power transfer may also be used for real-time powering of systems and/or devices without or in addition to charging. The above-described embodiments may also be used with such systems.

4. Shielding

As described above, the shielding helps to attenuate the electromagnetic flux emitted from the induction coils 14, 57, 77, thereby mitigating electromagnetic interference with the signals induced in the sensing coils of the sensing arrays 45, 55, 75. Sense rods 44, 54, 74 according to the disclosed embodiments may incorporate more shielding material than a sensing array because sense rods 44, 54, 74 occupy a smaller area relative to scan regions 48, 58, 78.

5. Advantages of the invention

The disclosed embodiments may have one or more of the following advantages:

the sensing bars 44, 54, 74 are small relative to the size of the sensing regions 48, 58, 78 that they need to scan. Sense bars 44, 54, 74 are movable to scan the entire sensing region 48, 58, 78. The combination of the dimensions of the bars 44, 54, 74 (relative to the dimensions of the sensing regions 48, 58, 78) and the means of moving the sensing bars 44, 54, 74 ensures that the wireless charging pads 40, 50, 70 are able to detect the presence of a foreign object 42, 52, 72, regardless of the dimensions of the foreign object 42, 52, 72, where the foreign object 42, 52, 72 is located within the sensing regions 48, 58, 78, or whether the foreign object 42, 52, 72 is stationary.

The small area of the sense rods 44, 54, 74 limits the amount of coil material and/or limits the number of sense coils 45, 55, 75 that can be placed. Thus, fewer supporting electronic components are required, resulting in a simpler electronic circuit to manufacture and repair. And therefore cheaper to manufacture and maintain.

The sensing bars 44, 54, 74 may have more shielding than is possible with a sensing array that covers most of the sensing area 48, 58, 78 of the wireless charging pads 40, 50, 70. The additional shielding that the sensing stem 44, 54, 74 may have means that the sensing coil 45, 55, 75 gets less interference from the electromagnetic flux generated by the induction coil 14, 57, 77, while still ensuring that there is a sufficient rate of sufficient wireless power transfer from the wireless charging pad 40, 50, 70 to the electric vehicle 11. Because the sensor coil array 45, 55, 75 requires a smaller shielding area, a higher level of shielding (e.g., thickness) around the sensor coil array 45, 55, 75 can be provided without impeding the operation of the wireless power transfer coil 14, 57, 77. The additional shielding reduces electromagnetic interference from the wireless power transfer coils 14, 57, 77, which improves the quality of the signals sensed by the sensor coil arrays 45, 55, 75. This improves the accuracy and/or precision of the measurement of the sensor coil array 45, 55, 75. Furthermore, the additional shield thickness allows the controller 32 to be placed closer to the sensor coil arrays 45, 55, 75. Physically placing the controller 32 closer to the sensor coil array 45, 55, 75 also improves the accuracy and/or precision of the sensor coil array 45, 55, 75 measurements.

As shown in fig. 11, 12, prior art arrangements typically include an array of sensing coils (referred to herein as a "sensing array") located beneath the charging surface (referred to herein as a "sensing region") of the wireless charging pad. The sensing coil array typically spans the entire (or at least a majority) of the charge pad region. The large size of the sensing array relative to the size of the wireless charging pad is problematic for several reasons:

first, prior art arrangements that use sensor coils to sense foreign objects can only detect foreign objects if the inductive measurement ("high" and/or "non-zero") indicating the presence of a foreign object can be referenced to a weaker or substantially absent ("low" and/or "zero") measurement indicating the absence of a foreign object. Prior to operation, the prior art is calibrated so that the system can distinguish between "high" and "low" measurements and/or between "non-zero" and "zero" measurements. If a stationary foreign object is located on the mat during start-up, the prior art arrangement will not be able to detect the foreign object. This is because the sensing array is so large that it always senses the presence of a foreign object; and because there are always no "low" and/or "zero" measurements, "high" and/or "non-zero" measurements are "misinterpreted" as indeterminate measurements. In the example shown in fig. 9 and 10, the foreign object is positioned such that a portion of the sensing array always "overlaps" with the foreign object.

Second, the wireless charging pad covers a relatively large surface area that requires scanning for foreign objects. The prior art arrangement requires a large number of sensing coils so that foreign objects can be scanned across the charging pad. This means that a large amount of coil material is required. Furthermore, in order to detect small foreign objects (which may be at least as small as a hair pin or paper clip, for example), it is necessary to place the sensing coils very close together to enable high resolution sensing. This arrangement of the sensing coil exacerbates the problem of requiring the large amount of coil material required to manufacture the wireless charging pad.

Third, the sensing array has shielding material to attenuate the electromagnetic flux emitted from the induction coil so that electromagnetic interference with signals induced in the sensing coils of the sensing array is mitigated. The shielding material should still be sufficiently magnetically "porous" so that the electromagnetic flux emitted from the induction coils can still pass through so that sufficient wireless transmission power is still present. Referring back to the example of FIG. 11, the size of the sensing array is large relative to the top surface of the sensing array, which limits how much shielding material can be applied to the upper limit of the sensing array. Excessive shielding will limit the rate of wireless power transfer from the wireless charging pad to the electric vehicle.