Abstract
The objective of this paper is to study a 22 kW high-power wireless power transfer (WPT) system for battery charging in electric vehicles (EVs). The proposed WPT system consists of a three-phase half-bridge LC–LC (i.e., primary LC/secondary LC) resonant power converter and a three-phase sandwich wound coil set (transmitter, Tx; receiver, Rx). To transfer power effectively with a 250 mm air gap, the WPT system uses three-phase, sandwich-wound Tx/Rx coils to minimize the magnetic flux leakage effect and increase the power transfer efficiency (PTE). Furthermore, the relationship of the coupling coefficient between the Tx/Rx coils is complicated, as the coupling coefficient is not only dominated by the coupling strength of the primary and secondary sides but also relates to the primary or secondary three-phase magnetic coupling effects. In order to analyze the proposed three-phase WPT system, a detailed equivalent circuit model is derived for a better understanding. To give a design reference, a novel coil design method that can achieve high conversion efficiency for a high-power WPT system was developed based on a simulation-assisted design procedure. A pair of magnetically coupled Tx and Rx coils and the circuit parameters of the three-phase half-bridge LC–LC resonant converter for a 22 kW WPT system are adjusted through PSIM and CST STUDIO SUITE™ simulation to execute the derivation of the design formulas. Finally, the system achieved a PTE of 93.47% at an 85 kHz operating frequency with a 170 mm air gap between the coils. The results verify the feasibility of a simulation-assisted design in which the developed coils can comply with a high-power and high-efficiency WPT system in addition to a size reduction.
Highlights
Electric vehicles (EVs) have the potential to serve as a solution to reducing petroleum consumption and as an alternative for replacing conventional fuel vehicles globally [1,2]
The results indicate the effectiveness of the developed coil design method
To validate the derived equation of the proposed wireless power transfer (WPT) system, the circuit schematic was drawn with PSIM software as shown in Figure 10; parameters listed
Summary
Electric vehicles (EVs) have the potential to serve as a solution to reducing petroleum consumption and as an alternative for replacing conventional fuel vehicles globally [1,2].Major vehicle manufacturers are developing pure battery EVs, hybrid EVs (HEVs), and plug-in hybrid EVs (PHEVs) as their next-generation products [3,4]. Electric vehicles (EVs) have the potential to serve as a solution to reducing petroleum consumption and as an alternative for replacing conventional fuel vehicles globally [1,2]. EVs can help reduce global oil and gas depletion and environmental issues, the technology gap remains. EVs have limited mileage and battery capacity, longer charging periods, and higher overall costs. They require charging cables, galvanic isolation components, battery chargers, and battery safety qualifications [5]. Humidity, metallic particles, and air exposure can cause oxidation or rust on the charging gun for EVs due to long-term usage. Rust may cause overheating and potential fire risks when executing high-current transmissions during EV battery charging. As the demand for higher battery capacity continues to grow, so does the size of the charging guns
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