OMAR UACAAA
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`US 20040130916A1
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`as) United States
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`a2) Patent Application Publication 0) Pub. No.: US 2004/0130916 Al
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` Baarman (43) Pub. Date: Jul. 8, 2004
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`(76)
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`Filed:
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`(54) ADAPTIVE INDUCTIVE POWER SUPPLY
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`Inventor: David W. Baarman, Fennville, MI
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`(US)
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`Correspondence Address:
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`Warner Norcross & Judd LLP
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`900 Fifth Third Center
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`111 Lyon Street, N.W.
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`Grand Rapids, MI 49503-2487 (US)
`(21) Appl. No.:
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`Oct. 20, 2003
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`Related U.S. Application Data
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`(63) Continuation-in-part of application No. 10/175,095,
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`filed on Jun. 18, 2002, now Pat. No. 6,673,250, which
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`is a continuation-in-part of application No. 09/592,
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`194, filed on Jun. 12, 2000, now Pat. No. 6,436,299.
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`(60) Provisional application No. 60/444,794,filed on Feb.
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`4, 2003. Provisional application No. 60/140,159, filed
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`on Jun. 21, 1999. Provisional application No. 60/140,
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`090, filed on Jun. 21, 1999.
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`Publication Classification
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`(SV)
`Tint. C07 eeeeeccceecccceeeeeccssneteeeceetneeeecnneess H02M 3/335
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`(52) U.S. C1. ee ecceeesseeseecnsecnsenecereestessneneeesnees 363/21.02
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`ABSTRACT
`(67)
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`A contactless power supply has a dynamically configurable
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`tank circuit powered by an inverter. The contactless power
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`supply is inductively coupled to one or more loads. The
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`inverter is connected to a DC power source. When loads are
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`added or removed from the system, the contactless power
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`supply is capable of modifying the resonant frequency of the
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`tank circuit, the inverter frequency, the inverter duty cycle or
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`the rail voltage of the DC powersource.
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`f
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`18
`12
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`CURRENT
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`SENSE
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`MICROPROCESSOR
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`WAVE SHAPER
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`MULTI-TAP
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`AND DRIVE
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`PRIMARY
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`CIRCUIT
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`DRIVE
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`OUTPUT
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`SWITCHING
`TAP
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`CAPACITANCE
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`SWITCH
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`CONTROL
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`LINES INDUCTANCE
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`SWITCH
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`Page 1 of 15
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`Volkswagen Exhibit 1005
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`Volkswagen Exhibit 1005
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`Patent Application Publication
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`Jul. 8, 2004 Sheet 1 of 6
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`12
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`18
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`CURRENT
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`SENSE
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`10
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`WAVE SHAPER
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`MULTI-TAP
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`AND DRIVE
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`CIRCUIT
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`PRIMARY
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`DRIVE
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`TAP
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`SWITCHING
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`CONTROL
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`SWITCH
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`INDUCTANCE
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`SWITCH
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`MICROPROCESSOR
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`LINES
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`FIG. 1
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`Patent Application Publication
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`Jul. 8, 2004 Sheet 2 of 6
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`US 2004/0130916 Al
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`CGOl
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`cord
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`~k
`poor wrororo rr wm em nme prem rem wee
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`A6L+
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`A6l+
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`Page 3 of 15
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`Patent Application Publication
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`Jul. 8, 2004 Sheet 3 of 6
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`US 2004/0130916 Al
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`LOAD PRESENT?
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`YES
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`TURN BALLAST ON
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`ADJUST BALLAST FREQUENCY
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`AS NEEDED BETWEEN LIMITS
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`IS THE
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`LOCK THIS VALUE
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`MONITOR CURRENT
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`LIMIT AND RANGE
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`ADJUST SWITCHED
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`INDUCTANCE AS NEEDED
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`FINE TUNE USING
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`SWITCHED CAPACITANCE
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` i SENSE LOAD INDUCTIVELY
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` NO
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`ae:
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`LOAD CHANGED?
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`FIG.
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`Patent Application Publication
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`Jul. 8, 2004 Sheet 4 of 6
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`US 2004/0130916 Al
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`a I
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`LA
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`CCE
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`Z0€
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`YOSNAS
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`LINDY SOE
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`Patent Application Publication
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`Jul. 8, 2004 Sheet 5 of 6
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`US 2004/0130916 Al
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`SET INITIAL RESONANT FREQUENCY,
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`INVERTER FREQUENCY, a 402
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`DUTY CYCLE, AND RAIL VOLTAG
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`SET NOMINAL RANGE FOR
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`OPERATING PARAMETERS
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`404
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`FIG. SA
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`406
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`IDLE
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`NOMINAL RANGE?
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`ARE OPERATING
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`PARAMETERS WITHIN
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`408
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`NO
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`CHANGE DUTY CYCLE OF INVERTER AND
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`STORE DUTY CYCLE INFO IN MEMORY
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`CURRENT OPERATING
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`PARAMETERS WITHIN
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`NOMINAL RANGE?
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`BEST
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`KNOWN SETTING FLAG
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`SET?
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`414
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`ARE
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`CURRENT OPERATING
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`PARAMETERS APPROXIMATELY EQUAL
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`TO EXPECTED OPERATING
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`PARAMETERS?
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`248
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`CLEAR BEST
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`KNOWN SETTING FLAG
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`Patent Application Publication
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`Jul. 8, 2004 Sheet 6 of 6
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`US 2004/0130916 Al
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`US 2004/0130916 Al
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`Jul. 8, 2004
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`toothbrush, while a CEETS for a rechargeable telephone
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`works only with a specific type of telephone. While this
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`solution allows the CEET to operate effectively with one
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`particular device, it fails to be sufficiently flexible to allow
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`the power supply to operate with different rechargeable
`devices.
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`[0009] Obviously, making a CEETS for each specific
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`chargeable device is costly and inefficient. Thus, a system
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`for contactless energy transmission which is efficient and
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`can be used with a large variety of devices is highly
`desirable.
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`ADAPTIVE INDUCTIVE POWER SUPPLY
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`RELATED APPLICATIONS
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`[0001] This application claims priority to and benefit of
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`USS. Provisional Application No. 60/444,794, entitled Adap-
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`tively Inductively Coupled Ballast Circuit, by David W.
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`Baarman,filed Feb. 4, 2003. The full disclosure of the prior
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`application is incorporated herein by reference. This appli-
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`cation is a continuation-in-part of U.S. patent application
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`Ser. No. 10/175,095 entitled Fluid Treatment System, which
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`was filed on Jun. 18, 2002, which is a continuation-in-part
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`of U.S. patent application Ser. No. 09/592,194,entitled Fluid
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`Treatment System, which wasfiled on Jun. 12, 2000. U.S.
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`patent application Ser. No. 09/592,194 claims the benefit
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`under 35 U.S.C. §119(e) of U.S. provisional patent appli-
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`cation Serial No. 60/140,159 entitled Water Treatment Sys-
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`tem with an Inductively Coupled Ballast, which wasfiled on
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`Jun. 21, 1999, and U.S. provisional patent application Serial
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`No. 60/140,090,entitled Point-of-Use Water Treatment Sys-
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`tem, which wasfiled on Jun. 21, 1999.
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`[0002] This application incorporates by reference the fol-
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`lowing applications filed on the same date and assigned to
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`the same assignee as this application: Adaptive Inductive
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`Power Supply with Communication, Serial No.
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`Inductive Coil Assembly, Serial No.
`; Electrostatic
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`Charge Storage Assembly, Serial No.
`, and Adapter,
`Serial No
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`BACKGROUND OF THE INVENTION
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`[0003] This invention relates generally to contactless
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`powersupplies, and morespecifically to inductively coupled
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`contactless power supplies.
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`[0004] Contactless energy transmission systems (CEETS)
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`transfers electrical energy from one device to another with-
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`out any mechanical connection. Because there is no
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`mechanical connection, CEETS have many advantages over
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`conventional energy systems. They are generally safer
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`becausethereis little danger of sparks or electric shocks due
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`to the isolation of the power supply. They also tend to have
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`a longerlife since there are no contacts to become worn. Due
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`to these advantages, CEETS have been used in everything
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`from toothbrushes to portable telephonesto trains.
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`[0005] CEETS are composed of power supplies and
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`remote devices. The remote devices could be chargeable,
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`such as batteries, micro-capacitors, or any other chargeable
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`energy source. Alternatively, CEETS could directly power
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`[0006] One kind of CEETS uses magnetic induction to
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`transfer energy. Energy from a primary winding in the power
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`supply is transferred inductively to a secondary winding in
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`the chargeable device. Because the secondary winding is
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`physically spaced from the primary winding, the inductive
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`coupling occurs through theair.
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`[0007] Without a physical connection between the primary
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`winding and the secondary winding, conventional feedback
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`control is not present. Thus, control of the energy transfer in
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`a CEETSfrom the primary to the secondary is difficult.
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`[0008] One commonsolution is to design a CEETS dedi-
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`cated to one type of device. For example, a CEETSfor a
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`rechargeable toothbrush is designed only for recharging a
`Page 8 of 15
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`SUMMARYOF THE INVENTION
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`[0010] The aforementioned problems are overcomein the
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`present invention.
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`[0011] Acontactless power supply inductively couples by
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`way of a tank circuit to a device. The power supply has a
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`controller for dynamically adjusting the resonant frequency
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`variable capacitor or a variable inductor, or both. In one
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`embodiment, the power supply also may have an inverter. A
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`drive circuit connected to the inverter controls the frequency
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`ofthe inverter and the duty cycle of the inverter. A controller
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`with an attached memory directs the operation of the
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`inverter by way of the drive circuit. Alternatively, The
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`inverter may also be connected to a DC powersource. The
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`controller could then change the rail voltage of the DC
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`[0012] By altering the resonant frequency of the tank
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`circuit, the frequency of the inverter, the duty cycle of the
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`inverter and the rail voltage of the power supply,
`the
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`contactless power supply can energize a variety of different
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`devices. The power supply can even energize several dif-
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`ferent devices at the same time. This ability to power a
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`multitude of different devices overcomes many of the limi-
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`tations previously associated with CEETS. Further, because
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`the power supply can energize a variety of different devices,
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`a central single source for supply powerto a variety of small
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`electronic devices is possible.
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`[0013]
`In one embodiment, a sensor may also coupled to
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`the tank circuit. It would monitor various operational char-
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`acteristics of the tank circuit, such as the phase of the current
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`within the tank circuit. These operation characteristics are
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`indicative of the total load energized by the power supply.
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`Whenthe operational characteristics indicate that the power
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`supply is not efficiently supplying power to the load, the
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`controller causes the power supply to seek an improved
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`configuration.
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`[0014] The process of seeking an improved configuration
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`may include one or more of the following steps. The power
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`supply could automatically attempt to compensate by chang-
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`ing the frequency of the inverter and the duty cycle of the
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`inverter. If this sufficiently correct
`the efficiency of the
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`powersupply, the controller causes the tank circuit to change
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`its resonant frequency. As is well known,
`the resonant
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`frequency of a tank circuit is in fact a range centered about
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`a frequency. The tank circuit will resonate at frequencies
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`which are approximately the resonant frequency. However,
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`the adaptive power supply described herein reconfigures the
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`tank circuit to have a substantially different resonant fre-
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`quency.
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`Page 8 of 15
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`

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`US 2004/0130916 Al
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`Jul. 8, 2004
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`[0015] The tank circuit may consist of either a variable
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`inductor or a variable capacitor or both. The controller
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`would then change the inductanceof the variable inductor or
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`the capacitance of the variable capacitor, or both,
`thus
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`causing the tank circuit to have a different resonant fre-
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`quency.
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`[0016] The controller may also establish a new rail voltage
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`the DC power source.
`It also sets a new inverter
`for
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`frequency and a new duty cycle for
`the inverter. The
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`adaptive power supply then operates with the new configu-
`ration.
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`[0017]
`If the adaptive power supply is still not operating
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`effectively,
`the power supply will once again attempt to
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`rectify the problem by changing the frequency of the
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`inverter and the duty cycle of the inverter. If the problem is
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`still not corrected, then the power supply will repeat the
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`process of reconfiguring the tank circuit, setting a new
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`inverter frequency and setting a new duty cycle.
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`[0018] This power supply continually searches for the
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`most efficient settings to deliver power to the devices.
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`However, if none of the various settings delivers power
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`efficiently to the devices, then the power supply will select
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`the mostefficient of the previous configurations and operate
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`the power supply with those settings.
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`[0019] Thus, the power supply efficiently powers a variety
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`of loads. Further, because the power supply is contactless, a
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`user does not need to have a multitude of different power
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`supplies or connectors.
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`[0020] These and other objects, advantages and features of
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`the invention will be more readily understood and appreci-
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`ated by reference to the detailed description of the drawings.
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`BRIEF DESCRIPTION OF THE DRAWINGS
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`[0021]
`FIG.1 is a block diagram of an adaptive inductive
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`ballast in accordance with one embodiment of the present
`invention.
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`[0022] FIG. 2 is a schematic diagram of the resonance-
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`seeking ballast of the attached patent application marked to
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`show changesto incorporate the adaptive inductive ballast
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`of the present invention.
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`[0023]
`FIG.3 is a flow chartillustrating operation of the
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`adaptive inductive ballast.
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`FIG.4 is a block diagram for an adaptive contact-
`[0024]
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`less energy transmission system.
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`[0025] FIGS. 5A and 5B are a flow chart showing the
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`operating of an adaptive contactless energy transmission
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`system.
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`DETAILED DESCRIPTION OF THE DRAWINGS
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`[0026] The present invention provides an adaptive induc-
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`tive ballast circuit
`in which the inductance and/or the
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`capacitance of the powersupply circuit is variable to provide
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`a broad range of adaptability, thereby permitting the ballast
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`circuit to power a variety of inductively powered devices
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`with widely differing load characteristics. For purposes of
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`disclosure, the present invention is described in connection
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`with a resonance-seeking ballast circuit, and more particu-
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`larly in connection with the inductive ballast described in
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`USS. patent application Ser. No. 10/246,155 entitled “Induc-
`Page 9 of 15
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`tively Coupled Ballast Circuit,” which incorporated by
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`reference into this application in its entirety. The present
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`invention is, however, well suited for use with other induc-
`tive ballast circuits.
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`[0027] A block diagram showing the general construction
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`of an adaptive inductive ballast 10 in accordance with one
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`embodimentof the present invention is shown in FIG.1. As
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`the adaptive inductive ballast 10 generally
`illustrated,
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`includes a microprocessor 12 that controls operation of the
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`circuit, a multi-tap primary 14 for generating a magnetic
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`field, a wave shaper and drive subcircuit 16 that generates
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`the signal applied to the primary 14, a current sense subcir-
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`cuit 18 that monitors the signal applied to the primary 14 and
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`provides corresponding feedback to the microprocessor 12,
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`a capacitance switch 20 for adjusting the capacitance values
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`in the wave shaper and drive subcircuit 16, and an induc-
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`tance switch 22 for adjusting the inductance of the multi-tap
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`primary 14. The microprocessor is a conventional micro-
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`processor widely available from a variety of suppliers.
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`[0028] The capacitance switch 20 generally includes two
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`banks of capacitors and a plurality of switches, such as
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`transistors, that are selectively actuatable by the micropro-
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`cessor 12 to control the values of the two capacitor banks.
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`The capacitors in each bank can be arranged in series or
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`parallel depending on the desired range and distribution of
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`possible capacitance values. The first bank of capacitors
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`replace capacitor 271 of the pre-existing resonance-seeking
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`ballast shown in the above referenced application. Similarly,
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`the second back of capacitors replace capacitor 272 of the
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`pre-existing resonance-seeking ballast shown in the above
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`referenced patent application.
`In effect,
`the capacitance
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`switch 20 makes capacitors 271 and 272 from the pre-
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`existing resonance-seeking ballast into variable capacitors,
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`the values of which are controlled by the microprocessor 12.
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`Alternatively, the described capacitance switch 20 can be
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`replaced by other circuitry capable of providing variable
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`capacitance.
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`[0029] The inductance switch 22 generally includes a
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`multi-tap primary 14 and a plurality of switches, such as
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`transistors, that are selectively actuatable by the micropro-
`cessor 12 to control the values of the inductance of the
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`primary 14. The multi-tap primary 14 replaces primary 270
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`of the pre-existing resonance-seeking ballast shown in the
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`attached patent application. In effect, the inductance switch
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`22 makes primary 270 from the pre-existing resonance-
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`seeking ballast into a variable inductance coil by varying the
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`number of turns in the primary 14, the value of which is
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`controlled by the microprocessor 12. Alternatively,
`the
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`described inductance switch 22 can be replaced by other
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`circuitry capable of providing variable inductance.
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`[0030]
`In general operation,
`the microprocessor 12 is
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`programmedto receive input from the current sense subcir-
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`cuit 18, which is indicative of the current applied to the
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`primary 14. The microprocessor 12 is programmedto sepa-
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`rately adjust the capacitance switch 20 and the inductance
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`switch 22 to cycle through the range of capacitance values
`and inductance values available to the circuit. The micro-
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`processor 12 continues to monitor the input from the current
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`sense circuit 18 while adjusting the capacitance and induc-
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`tance values to determine which values provide optimum
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`current to the primary 14. The microprocessor 12 then locks
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`the adaptive ballast into the optimum settings.
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`Page 9 of 15
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`

`

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`US 2004/0130916 Al
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`Jul. 8, 2004
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`[0031] Some of the changes required to adapt the reso-
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`nance-seeking inductive ballast of the application patent
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`application into an embodiment of the adaptive inductive
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`ballast circuit 10 are noted in the schematic diagram of FIG.
`2.
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`[0032] While the pre-existing resonance-seeking ballast is
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`described in greater detail in U.S. patent application Ser. No.
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`10/246,155, an overview of the circuit may be helpful to a
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`fuller understanding of this invention. A ballast feedback
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`circuit
`is connected at point A and a control circuit
`is
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`connected at point B. Oscillator 144 provides half bridge
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`inverter 148 with an alternating signal by wayof drive 146.
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`Half bridge inverter powers tank circuit 150. Current sens-
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`ing circuit 218 provides feedback to oscillator 144. The
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`feedback circuit, control circuit, oscillator, half bridge
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`inverter, drive and current sensing circuit 218 as well as
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`other supporting circuitry is more fully described in the
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`above referenced patent application.
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`In FIG.2, a phase delay could be inserted at E and
`[0033]
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`can be controlled as a delay line or even DSP (Digital Signal
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`Processing) could be usedto delay this signal. This delay can
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`be used to throttle the phase and control secondary ampli-
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`tude. At F, switched capacitance can adjust the resonant
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`frequency based on the adjustable primary inductance.
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`Simple transistors can be used to switch in and out capaci-
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`tance. The capacitance is changed whenthe primary induc-
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`tor changes as to match load. At G, primary inductance can
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`be switched to adjust the power required by the secondary
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`circuit. With that load information, the control processor can
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`adjust
`the inductance as needed to provide the power
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`required. The inductance can be switched using transistors
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`and multiple taps from the primary inductor controlled by
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`the microprocessor.
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`[0034] The operating sequence of the adaptive inductive
`ballast circuit is described in more detail in connection with
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`FIG. 3. In operation, the illustrated system waits until it
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`determines that a load is present before applying power to
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`the primary 14. This will save power and may be done by
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`providing each inductively powered device with a magnet
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`that actuates a reed switch adjacent to the primary. Alterna-
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`tively, a user-actuated switch (not shown) may be provided
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`so that the user can engage the power supply when an
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`inductively powered device is present. As another alterna-
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`tive, the inductively powered device may be configured to
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`mechanically actuate a switch whenit is placed into located
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`by the primary to signal its presence. As a further alternative,
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`the switching mechanism can be eliminated and the ballast
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`circuit can provide powerto the primary 14 regardless of the
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`presence of a load.
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`[0035] Once the power supply circuit is activated,
`the
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`circuit adjusts its frequency to optimize the current applied
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`to the primary. After the appropriate operating frequency has
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`been determined at initial capacitance and inductance val-
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`the microprocessor locks the ballast circuit into the
`ues,
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`operating frequency and then begins to cycle through the
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`range of inductance values available through the multi-tap
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`primary. After each change in inductance value, the micro-
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`processor unlocks the operating frequency and permits the
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`ballast circuit to seek resonance, settling at a frequency that
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`provides optimal current to the primary. The microprocessor
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`continues cycling through the available inductance values
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`until it has determined which value provides optimal current
`Page 10 of 15
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`to the primary. In one embodiment, a progressive scanning
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`process is used to determine the appropriate inductance
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`value. This is achieved bystarting the scanning process with
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`the lowest inductance value, and sequentially stepping up
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`the inductance value until the change in inductance value
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`results in a reduction in the current applied to the primary.
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`The microprocessor will then step back down one induc-
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`tance value, where the greatest current was achieved. Alter-
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`natively, the scanning process may begin with the highest
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`inductance value, and sequentially step down the inductance
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`value until
`the change in inductance value results in a
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`reduction in the current applied to the primary. The micro-
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`processor will
`then step back up one inductance value,
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`where the greatest current was achieved. As another alter-
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`native, the microprocessor can step through each inductance
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`value to determine the corresponding current, and after
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`stepping through each value, return to the inductance value
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`that provided the greatest current to the primary.
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`[0036] After the appropriate inductance value is deter-
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`mined,
`the microprocessor locks the circuit at the deter-
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`mined inductance value and begins to cycle through the
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`capacitance values. In one embodiment, the microprocessor
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`uses a progressive scanning technique to determine the
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`capacitance that provides the primary with the greatest
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`current. The scanning process may progress upwardly from
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`the lowest capacitance value or downwardly from the high-
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`est capacitance value, as described above in connection with
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`the scanning process for the inductance value. As an alter-
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`native to a progressive scanning process, the microprocessor
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`can step through each capacitance value to determine the
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`corresponding current, and after stepping through each
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`value, return to the capacitance value that provided the
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`greatest current to the primary.
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`In this embodiment, the frequency of the ballast
`[0037]
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`circuit 1s not permitted to vary once the appropriate induc-
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`tance value has been determined. The microprocessor can,
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`alternatively, be programmed to permit the ballast circuit to
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`seek resonance after each change in capacitance value.
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`[0038]
`In an alternative embodiment, the microprocessor
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`may be programmed to provide adjustment of only the
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`capacitance value or only the inductance value of the power
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`supply circuit. In the former alternative, the multi-tap pri-
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`mary can be replaced by a conventional single-tap primary
`and the inductance switch can be eliminated. In the latter
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`alternative, the capacitor bank can be replaced by a single set
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`of capacitors and the capacitance switch can be eliminated.
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`In another alternative embodiment, the microprocessor can
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`be programmed to adjust the capacitance before adjusting
`the inductance.
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`[0039] As noted above, the present inventionis not limited
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`to use in connection with a resonance-seeking ballast. In
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`other applications, a current sensor may be incorporated into
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`the ballast to provide input to the microprocessor that is
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`representative of the current being applied to the primary. In
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`operation without a resonance-seeking ballast, the micro-
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`processor will separately cycle through the various capaci-
`tance and inductance values to determine the values that
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`provide optimum powerto the primary.
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`[0040]
`In a further alternative embodiment, the adaptive
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`inductive ballast 10 may include phase delay circuitry (not
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`shown) that permits the ballast 10 to throttle the phase and
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`control secondary amplitude. The phase delay circuitry may
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`Page 10 of 15
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`US 2004/0130916 Al
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`Jul. 8, 2004
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`Controller 326 could be a microcontroller, such as an
`include a delay line or a Digital Signal Processor (DSP)that
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`8051-type microcontroller. Alternatively, controller 326
`is connected to the wave shaper and drive circuit 16 fol-
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`could be a microprocessor with additional supporting cir-
`lowing the operational amplifier 210.
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`cuitry.
`and concepts
`[0041] Further exemplifying the ideas
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`[0050] Controller 326 can modify the inductance of vari-
`expressed above, an additional embodiment for an adaptive
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`able inductor 330 or the capacitance of variable capacitor
`contactless energy transmission system is shown in the
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`332. This could be done, e.g., by switching in or out
`block diagram of FIG. 4. The adaptive contactless energy
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`additional capacitor or inductors or by changing the physical
`transmission system is comprised of adaptive inductive
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`characteristics of variable inductor 330 or variable capacitor
`power supply 305 and remote device 307.
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`332. By modifying the inductance of variable inductor 330
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`[0042] As is well know, power source 310 is a DC power
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`and the capacitance of variable capacitor 332, the resonant
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`source providing DC (direct current) power