Optically-coupled Switched-mode Converter forSmartphons Wireless Charging Application
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Optimal Power Sharing Speed Compensation in On-road Wireless EV Charging Systems
Dynamic wireless charging of electric vehicles (EV) is an emerging technology with the potential to address range anxiety and reduce the size of batteries or provide charge-sustaining operation. Charging demand for dynamic wireless charging systems (DWCS) varies greatly in response to location-specific traffic behaviors including the number and speed of vehicles. This paper highlights the potential reduction of load variation with speed compensation and simulates opportunities to maximize the number of cars charged concurrently through “power sharing” or altering power output to slower cars while maintaining a maximum delivered energy. An improved sub-minute model for synthetic traffic is proposed to effectively model DWCS load on high speed roadways and a power electronics model is created based on an existing prototype developed by ORNL to investigate the potential for power sharing. Reductions in the average speed of traffic can greatly increase instantaneous DWCS load by as much as 26%, complicating capacity sizing. Parametric studies with a LCC-S power electronics model shows feasible power reduction of more than 20%, while maintaining a maximum achievable efficiency greater than 90%. Speed compensation on a roadway with large speed variation can reduce average power expected by 21% and increase the maximum number of cars charged simultaneously by 30%. The application of power sharing may significantly reduce load variability due to speed, allow for increased car hosting capability, and guarantee a maximum energy delivered.
Lewis, Donovin D.↗
A Unified Off-Board Charging System for Integrated Wired and Wireless EV Charging
This work explores a unified off-board charger approach that enables both wired and wireless charging within a single system architecture. Instead of deploying two independent converters, the proposed configuration switches between an LLC-based operation for wired charging and an LCC-S–type operation for wireless charging by rearranging the excitation of commonly used components. With this reconfiguration, the same switch bridge, resonant elements, and magnetic coupling coils can be utilized in both modes without relying on relays or additional hardware paths. To assess the basic operation of the proposed system, PLECS circuit simulations were performed for both wired and wireless charging modes. A 3.3-kW prototype was also built, and representative experimental results for each mode confirm that the unified converter can operate properly while reducing hardware duplication.
Jo, Cheolhui [ORNL] (ORCID:0000000322692434)↗
Multi-phase Wireless Power Transfer with High Power Density Inductive Coils for Electric Drone Charging
Wireless charging of unmanned ground vehi-cles and aircraft has been proposed to increase charging reliability and security, allow for autonomous functionality, and either reduce battery size or increase continuous flight time. This paper proposes a three-phase Litz wire primary and a two-phase PCB secondary for high secondary-side power density considering misalignment tolerances, surface and volumetric power density, and coil sizing. Elec-tromagnetic 3D finite element analysis (FEA) simulations are conducted to study variation in mutual inductance and coupling coefficient with different secondary coil sizes and number of turns, horizontal and vertical misalignment between the primary and secondary, and a combination of both for a set of designs with the same rated power. Results indicate that receiver coils of reduced size relative to the primary can deliver rated power for increased power density and higher tolerance to misalignment.
Gastineau, Lucas [University of Kentucky]↗
Misalignment Tolerant Three-phase Wireless Fast Charging System for Electric Vehicles
This project proposes improving the technology level of the three-phase wireless charging technology developed at Oak Ridge National Laboratory (ORNL). Successful commercialization of wireless charging systems require that they meet strict safety standards for electromagnetic field emissions and interoperability with other wireless charging technology. ORNL has previously demonstrated a 50kW three-phase wireless power transfer system with 95% efficiency. This prototype system weighed less than 50% of similar high-power wireless charging system while simultaneously exhibiting better safety characteristics. Due to better material utilization, the reduction in mass is expected to translate into similar cost reduction for the magnetic coupler. Additionally, the smaller footprint of the system can ease vehicle integration difficulties that would be encountered using other technology. Furthermore, the three-phase design can be made to operate with existing single-phase coupler design more easily and without intentional physical misalignment which would otherwise pose safety issues.This project developed ORNL’s WPT technology to satisfy the specifications and requirements for electric vehicle (EV) charging. The result of the project will be a prototype and reference design for a high-power wireless charging system—including magnetics, power electronics, and controls—serving as a baseline for product development.
33 ADVANCED PROPULSION SYSTEMS↗
Misalignment Tolerant Three-phase Wireless Fast Charging System for Electric Vehicles
This project proposes improving the technology level of the three-phase wireless charging technology developed at Oak Ridge National Laboratory (ORNL). Successful commercialization of wireless charging systems require that they meet strict safety standards for electromagnetic field emissions and interoperability with other wireless charging technology. ORNL has previously demonstrated a 50kW three-phase wireless power transfer system with 95% efficiency. This prototype system weighed less than 50% of similar high-power wireless charging system while simultaneously exhibiting better safety characteristics. Due to better material utilization, the reduction in mass is expected to translate into similar cost reduction for the magnetic coupler. Additionally, the smaller footprint of the system can ease vehicle integration difficulties that would be encountered using other technology. Furthermore, the three-phase design can be made to operate with existing single-phase coupler design more easily and without intentional physical misalignment which would otherwise pose safety issues. This project developed ORNL’s WPT technology to satisfy the specifications and requirements for electric vehicle (EV) charging. The result of the project will be a prototype and reference design for a high-power wireless charging system—including magnetics, power electronics, and controls—serving as a baseline for product development.
33 ADVANCED PROPULSION SYSTEMS↗
Severe Temperature Impact Study on Ferrite Electromagnetic Shielding for Wireless Electric Vehicle Charging
Wireless charging of an electric vehicle (EV) is an emerging technology that enables noncontact charging, which has advantages in terms of convenience and flexibility. However, the embedded charging pads under and on the ground expose the charging coils, ferrite shielding, and related components to a potentially severe external environment. To study the electromagnetic shielding performance under such extreme temperature conditions, ferrite shielding material's permeability characteristics are tested under temperatures as low as -50°C to as high as 240°C. Referring to the official recorded lowest and highest temperature of the United States, in this paper, it is assumed that the operation temperature ranges from -50°C to 57°C as the coldest winter and hottest summer environment for WPT application. Electromagnetic performance, shielding, and associated stray magnetic emissions are simulated by using three-dimensional (3D) transient simulations to study the impact of low and high temperature on electromagnetic shielding performance. Based on ferrite testing data, from -50°C low temperature to 57°C high temperature, the ferrite's relative permeability ranges from 2550 to 3727. The simulation study indicates that there won't be significant impact on the EM shielding performance for WPT operated under those severe environment temperature conditions.
24 POWER TRANSMISSION AND DISTRIBUTION↗
Design and optimization of cancellation coil topologies for a ferrite-less wireless EV charging pad
Ferrite cores are widely used in conventional wireless EV charging pads to reduce stray EMF emissions, but they can be brittle, heavy, and expensive. This work furthers the development of ferrite-less wireless charging pads by comparing an active and two distinct passive cancellation coil topologies as candidates to replace the ferrite. Using the software packages FEMM and MATLAB, each topology is optimized to find the best winding positions and radii to minimize leakage at a specified position under the side of the vehicle. The optimized designs are compared for shielding effectiveness, induced current, and efficiency. All three topologies are able to sufficiently reduce the leakage field below the ICNIRP limit of 27 μTrms with just one turn. Interestingly, we find that an array of simple passive cancellation loops performs similar to the more widely studied passive cancellation coil.
Scher, Aaron D.↗
ORNL Experience and Challenges Facing Dynamic Wireless Power Charging of EV's
As visionary as dynamic, or in-motion, wireless charging of electric vehicles appears the concept is well over a century old as this paper will show. This is because the concept of magnetic induction dates back to the pioneering work of physicist Michael Faraday in the early 19th century. Today wireless power transfer (WPT) is being standardized for stationary and quasi-stationary charging of electric vehicles (EV). The Society of Automotive Engineers (SAE) has undertaken the standardization of stationary charging and will make this public during 2016. In addition to this the IEEE-SA (Standards Activities) initiated standards development for EV?s in their EVWPT working group in 2012. This study introduces the many challenges facing EVWPT in not only high power transfer to a moving vehicle and energy management at a utility scale, but communications in a vehicle to infrastructure (V2I) environment and management of high data rates, ultra-low latency, and dealing with communications loss in dense urban areas. Finally, future concepts such as guideway powering of EV?s are presented to illustrate one technical trajectory EVWPT may take.
29 ENERGY PLANNING, POLICY, AND ECONOMY↗
A Modular Integration Design of LCL Circuit Featuring Field Enhancement and Misalignment Tolerance for Wireless EV Charging
One of the major challenges of high-order wireless charging circuit is to reduce the system volume and cost induced by its additional components. Based on an LCL-S circuit, this paper proposes a modular integration design, in which an identical compensation inductor and transmitter are closely coupled. A new compensation method is derived to enable zero phase angle (ZPA) and constant current (CC) output. Identical currents are fed into the same reference terminals of both inductors to enable transmission field enhancement and to eliminate reactive power flow between the inductors. A misalignment tolerant coil is used to improve the output power stability under random parking imperfection. The proposed integration design achieves enhanced transmission capacity. Experiments are carried out to verify the proposed design.
Zhang, Pengcheng↗
Wireless power charging using point of load controlled high frequency power converters
An apparatus for wirelessly charging a battery of an electric vehicle is provided with a point of load control. The apparatus includes a base unit for generating a direct current (DC) voltage. The base unit is regulated by a power level controller. One or more point of load converters can be connected to the base unit by a conductor, with each point of load converter comprising a control signal generator that transmits a signal to the power level controller. The output power level of the DC voltage provided by the base unit is controlled by power level controller such that the power level is sufficient to power all active load converters when commanded to do so by any of the active controllers, without generating excessive power that may be otherwise wasted.
24 POWER TRANSMISSION AND DISTRIBUTION↗
An Integrated Electric Vehicle Drive Motor and Wireless Charger
This work proposes an in-wheel electric vehicle-motor in which the motor windings also act as receiver coils in a wireless charging system. Vehicle wireless charging systems normally include a receiver coil, compensation network, rectifier and battery charger. The proposed concept would eliminate the need for a separate receiver coil. Studies based on two-dimensional finite element analysis are carried out to verify the feasibility of the concept. An external rotor Halbach array rotor with single layer fractional slot concentrated wingdings is found to be a suitable motor topology which would enable the use of one or more motor coils as a receiver coil. The paper also discusses the design modifications and considerations required to enable this.
Rallabandi, Vandana↗
Optimum Planning for Inductively Charged On-Demand Automated Electric Shuttles at Greenville, South Carolina
Wireless charging technology presents perfect fits for autonomous electric vehicles for realizing a fully automated system (vehicle and charger). This paper presents a planning optimization analysis for a pilot project of in-route wireless charging infrastructure serving fixed-route on-demand shared automated electric shuttles (SAESs) at Greenville, South Carolina, USA. A single-objective non-linear integer planning optimization problem is formulated. A comprehensive cost function representing the inductively charged SAESs is developed, considering road construction, power electronics and materials, traction battery, and installation costs. The optimization problem is solved to determine the best combination of the system key design parameters (number and allocations of wireless chargers, charging power level, track length and on-board battery capacity) that show the most cost-effective solution and allow the SAESs realizing charge sustaining operation. The planning platform incorporates representative simulated traffic data (drive cycles and routes) for four SAESs at Greenville project using the Simulation of Urban Mobility (SUMO) tool. These data are fed to a vehicle powertrain model and a wireless charger power model to predict the battery power, energy and state-of-charge (SOC) profiles, which are provided to the search algorithm to assess the design objectives under specific constraints. The results indicated that implementing wireless charging at a few designated stops for fixed-route SAESs with proper design allows the vehicles realizing charge sustaining operation, infinite range and zero recharge downtime, with a significant reduction in the on-board battery (36 % ) and road coverage (69%), at minimum cost.
33 ADVANCED PROPULSION SYSTEMS↗
A High-Voltage High-Reliability Scalable Architecture for Electric Vehicle Power Electronics (Final Report)
This project developed and demonstrated new composite converter technologies that lead to high power density (> 20 kW/L) at power levels of 10s of kW, 100s of kW, or possibly higher, with fundamental advances in converter efficiency and Q that lead to substantial increases in mean time to failure (MTTF). These advantages were realized through development of new composite converter topologies that perform buck, boost, or other conversion functions and that are scalable to higher voltage and power levels through sharing of voltage and current stresses among multiple dissimilar partial-power converter modules. The project led to experimental demonstration of a125 kW multifunction electric vehicle power conversion system having in-creased dc bus voltage (950 V nominal, 1200 V peak) that interfaces a 200 V to 400 V battery pack, and that includes integrated level 2 wired charging and wireless charging functions. The project incorporated SiC MOSFET modules having switching frequencies in excess of 100 kHz, planar magnetics, a hierarchical control architecture that enables scaling to higher voltages and powers with additional converter modules, and a high-power density in excess of 20 kW/L. The research demonstrated how a more complex converter approach can increase mean-time-to-failure, even though the number of elements is increased. This is achieved through significant reduction of temperature rise through fundamentally superior converter circuit topologies. The research also demonstrated new high power planar magnetics that increase power density. The technology is appropriate to a variety of applications including EV power trains, EV charging, PV inverters, battery storage, and similar areas. These systems potentially can be manufactured in the U.S.
33 ADVANCED PROPULSION SYSTEMS↗
A Field Enhancement Integration Design Featuring Misalignment Tolerance for Wireless EV Charging Using LCL Topology
This article proposes a magnetic integration design for EV wireless power transfer (WPT) systems, where the compensation and transmitting coils overlap one on top of the other to share the ferrite layer without any decoupling consideration. The magnetic field generated by both the compensation and transmitting coils are exploited to transfer power. To this end, a compensation method is proposed to enable magnetic field enhancement without any reactive power flow between the compensation and the transmitting coils, and to achieve input zero phase angle and constant current output. In addition, an efficient finite element analysis-based coil optimization algorithm is proposed to improve the coil misalignment tolerance on the horizontal plane, in which a reversely connected inner coil is used to stabilize the system output under misalignment conditions. Analytical and simulation results confirm transmission flux density enhancement and reduced leakage field characteristics of the proposed coil design. Finally, a scaled-down WPT prototype is built and tested to verify the performance and effectiveness of the design. The proposed design achieves 91.17% efficiency and misalignment tolerance up to 200 mm in any XY-direction while maintaining the power transfer and its efficiency. The results of this work provide insights into magnetic integration design of high-order compensation topologies featuring higher compactness, less ferrite usage, magnetic field enhancement, and misalignment tolerance for WPT systems.
42 ENGINEERING↗
NREL's Managed WPT Experiences and Lessons Learned
This presentation introduced NREL's vision for demonstrating wireless power transfer (WPT) for electric vehicles; described the 25-kW WPT system used with NREL's shuttle; summarized testing of the in-vehicle WPT system; discussed monitoring and control of the wireless charging; described a WPTsim Tool for wireless charging design; and presented a case study design project using WPTsim.
30 DIRECT ENERGY CONVERSION↗
Planning Optimization for Inductively Charged On-demand Automated Electric Shuttles Project at Greenville, South Carolina
Wireless charging technology presents an ideal fit for autonomous electric vehicles for realizing a fully automated system (vehicle and charger). This paper presents a planning optimization analysis for a pilot project of in-route wireless charging infrastructure serving fixed-route on-demand shared automated electric shuttles (SAESs) at Greenville, South Carolina, USA. A single-objective non-linear mixed integer system planning optimization problem is formulated. A comprehensive cost model representing the overall inductively charged SAESs system is developed, considering road construction, power electronics and materials, traction battery, and installation costs. The optimization problem is solved to determine the best combination of the system key design parameters (number and allocations of wireless chargers, charging power level, track length and on-board battery capacity) that show the most cost-effective solution and allow the SAESs to achieve charge-sustaining operation. The planning platform incorporates representative simulated traffic data (driving speed and routes) for four SAESs in the Greenville using the Simulation of Urban Mobility tool. These data are fed to a vehicle powertrain model and a wireless charger power model to predict the battery power, energy and state-of-charge profiles, which are provided to the search algorithm to assess the design objectives under specific constraints. Finally, the results indicate that implementing high-power (100 kW) wireless charger at a few designated stops for fixed-route SAESs with the proper track length allows the vehicles to realize charge-sustaining operation, infinite range, and zero recharge downtime, with a significant reduction in the on-board battery (36%) and road coverage (69%), at minimum cost.
33 ADVANCED PROPULSION SYSTEMS↗
Systems, methods and computer program products for charging autonomous wireless sensors in subsurface environments
Autonomous wireless sensors in subsurface environments can be charged while present in the subsurface environment to allow the sensors to measure and wirelessly transmit measurements. The sensors rely upon a contrast agent to provide a power flow path to the sensors.
Heath, Jason E.↗