Design Optimization of Inductive Power Transfer Systems for Contactless Electric Vehicle Charging Applications

Contactless Electric Vehicle (EV) charging based on magnetic resonant induction is an emerging technology that can revolutionize the future of the EV industry and transportation systems by enabling an automated and convenient charging process. However, in order to make this technology an acceptable alternative for conventional plug-in charging systems it needs to be optimized for different design measures. Specifically, the efficiency of an inductive EV charging system is of a great importance and should be comparable to the efficiency of conventional plug-in EV chargers. The aim of this study is to develop solutions that contribute to the design enhancement of inductive EV charging systems. Specifically, generalized physics-based design optimization methods that address the trade-off problem between several key objectives including efficiency, power density, misalignment tolerance, and cost efficiency considering critical constraints are developed. Using the developed design methodology, a 3.7kW inductive charging system with square magnetic structures is investigated as a case study and a prototype is built to validate the optimization results. The developed prototype achieves 93.65% efficiency (DC-to-DC) and a power density of 1.65kW/dm3. Also, self-tuning power transfer control methods with resonance frequency tracking capability and bidirectional power transfer control are presented. The proposed control methods enhance the efficiency of power converters and reduce the Electromagnetic Interference (EMI) by enabling soft-switching operations. Several simplified digital controllers are developed and experimentally implemented. The controllers are implemented without the use of DSP/FPGA solutions. Experimental tests show that of the developed simplified controllers can effectively regulate the power transfer around the desired value. Moreover, the experiments show that compared to conventional converters, the developed converters can achieve 4% higher efficiency at low power levels. Moreover, enhanced matrix converter topologies that can achieve bidirectional power transfer and high efficiency with a reduced number of switching elements are introduced. The self-tuning controllers are utilized to design and develop control schemes for bidirectional power transfer regulation. The simulation analyses and experimental results show that the developed matrix converters can effectively establish bidirectional power transfer at the desired power levels with soft-switching operations and resonance frequency tracking capability. Specifically, a direct three-phase AC-AC matrix converter with a reduced number of switches (only seven) is developed and built. It is shown that the developed converters can achieve efficiencies as high as 98.54% at high power levels and outperform conventional two-stage converters

Double Resonant High-Frequency Converters for Wireless Power Transfer

This thesis describes novel techniques and developments in the design and implementation of a low power radio frequency (40kHz to 1MHz) wireless power transfer (WPT) system, with an application in the wireless charging of autonomous drones without physical connection to its on-board Battery Management System (BMS). The WPT system is developed around a matrix converter exploiting the benefits such as a small footprint (DC-link free), high efficiency and high power density. The overall WPT system topology discussed in this thesis is based on the current state-of-the-art found in literature, but enhancements are made through novel methods to further improve the converter’s stability, reduce control complexity and improve the wireless power efficiency. In this work, each part of the system is analysed and novel techniques are proposed to achieve improvements. The WPT system design methodology presented in this thesis commences with the use of a conventional full-bridge converter. For cost-efficiency and to improve the converters stability, a novel gate drive circuit is presented which provides self-generated negative bias such that a bipolar MOSFET drive can be driven without an additional voltage source or magnetic component. The switching control sequences for both a full-bridge and single phase to single phase matrix converter are analysed which show that the switching of a matrix converter can be considered to be the same as a full-bridge converter under certain conditions. A middleware is then presented that reduces the complexity of the control required for a matrix converter and enables control by a conventional full-bridge controller (i.e. linear controller or microcontroller). A novel technique that can maximise and maintain in real-time the WPT efficiency is presented using a maximum efficiency point tracking approach. A detailed study of potential issues that may affect the implementation of this novel approach are presented and new solutions are proposed. A novel wireless pseudo-synchronous sampling method is presented and implemented on a prototype system to realise the maximum efficiency point tracking approach. Finally, a new hybrid wireless phase-locked loop is presented and implemented to minimise the bandwidth requirements of the maximum efficiency point tracking approach. The performance and methods for implementation of the novel concepts introduced in this thesis are demonstrated through a number of prototypes that were built. These include a matrix converter and two full WPT systems with operating frequencies ranging from sub-megahertz to megahertz level. Moreover, the final prototype is applied to the charging of a quadcopter battery pack to successfully charge the pack wirelessly whilst actively balancing the cells. Hence, fast battery charging and cell balancing, which conventionally requires battery removal, can be achieved without re-balance the weight of the UAV

Pregled stanja u području bezkontaktnog prijenosa električne energije: primjene, izazovi i trendovi

Methods of contactless electrical power transfer technologies have been surveyed and results are presented here. In this among, the inductive based contactless electrical power transfer systems are investigated in more detail. The principles, structures and operations of the systems as well as their methods presented in the literature are reviewed and their applications are explored. Also, current challenges and opportunities and future trends are noted. An effective index is proposed to compare different contactless power transfer systems describing their present statuses and the future trends. Finally, some remarks and recommendations regarding future studies are proposed.U radu je dan prikaz različitih tehnologija u području bezkontaktnog prijenosa električne energije. U radu je naglasak na indukcijom baziranim sustavima bezkontaktnog prijenosa električne energije. Pregledom literature utvrðeni su koncepti, strukture i način rada pojedinih sustava bezkonaktnog prijenosa kao i njihove primjene. Također, zabilježeni su trenutni izazovi, prilike i trendovi. Predložen je efektivni indeks za vrednovanje sustava bezkontaktnog prijenosa električne energije s ciljem komparativne analize različitih sustava opisanih trenutnim statusom i trendovima. Konačno, dan je kritički osvrt i predložene su preporuke za buduće studije

A New Methodology for Contactless Energy System Using Inductive Coil Positioning Flexibility

This paper portrays a system, Contactlesstransmission of electrical energyfrom a power source to an electrical load without interconnecting conductor. As of late, expanded remote power exchange frameworks innovation exploration has prompted frameworks with higher effectiveness. Contactless transmission is helpful in situations where interconnecting wires are badly arranged, incomprehensible or perilous. These days electrically worked hardware's are associated with the supply by means of plugs & sockets, however can be hazardous or have constrained life in the vicinity of dampness. In dangerous areas and in submerged applications, the Contactless EnergyTransmission System(CETS), by which electrical energy may be transmitted, without electrical association or physical contact, through nonmagnetic media of low conductivity. The CETS has been utilized to exchange up to 5kW over a 10-mm crevice, utilizes high-frequency attractive coupling and empowers module power associations will be made in dangerous natural conditions without the danger of electric shock, short-circuiting, or starting. With contactless Inductive Power Transfer (IPT), it is conceivable to exchange electrical energy to stationary or mobile consumers without contacts, links, or slip rings, another precise and particular configuration displayed in this paper

Challenges of Inductive Electric Vehicle Charging Systems in both Stationary and Dynamic Modes

Inductive power transfer as an emerging technology has become applicable in wide power ranges including Electric Vehicle, Electric Aircraft, wheelchair, cellphone, scooter and so on. Among them, inductive Electric Vehicle (EV) charging has gained great interest in the last decade due to many merits namely contactless technology, more convenience, full automotive charging process. However, inductive EV charging systems could bring about so many issues and concerns which are addressed in this dissertation. One of the critical challenges addressed in this dissertation is a virtual inertia based IPT controller to prevent the undesirable dynamics imposed by the EVs increasing number in the grid. Another adverse issue solved in this dissertation is detecting any metal object intrusions into the charging zone to the Inductive Power Transfer (IPT) systems before leading to heat generation on the metal or risk of fire. Moreover, in this dissertation, a new self-controlled multi-power level IPT controller is developed that enables EV charging level regulation in a wide range of power; suitable for different applications from golf-cart charging system (light duty EV) to truck (heavy duty EV). The proposed controller has many merits including easy to be implemented, cons-effective, and the least complexities compared to conventional PWM methods. Additionally, in this dissertation, the online estimation of IPT parameters using primary measurement including coupling factor, battery current and battery voltage is introduced; the developed method can find immediate applications for the development of adaptive controllers for static and dynamic inductive charging systems. Finally, the last objective of this research is physics-based design optimization techniques for the magnetic structures of inductive EV charging systems for dynamic application (getting charged while in motion). New configuration of IPT transmitting couplers with objective of high-power density, low power loss, low cost and less electromagnetic emission are designed and developed in the lab

A GaN-based wireless power and information transmission method using Dual-frequency Programmed Harmonic Modulation

Information transmission is often required in power transfer to implement control. In this paper, a Dual-Frequency Programmed Harmonic Modulation (DFPHM) method is proposed to transfer two frequencies carrying power and information with the single converter via a common inductive coil. The proposed method reduces the number of injection tightly coupled transformers used to transmit information, thereby simplifying the system structure and improving reliability. The performances of power and information transmission, and the method of information modulation and demodulation, as well as the principles of the control, are analyzed in detail. Then a simulation model is set up to verify the feasibility of the method. In addition, an experiment platform is established to verify that the single converter can transfer the power and information simultaneously via a common inductive coil without using tightly coupled transformers.Web of Science8498564984

Novel Roaming and Stationary Tethered Aerial Robots for Continuous Mobile Missions in Nuclear Power Plants

AbstractIn this paper, new tethered aerial robots including roaming tethered aerial robots (RTARs) for radioactive material sampling and stationary tethered aerial robots (STARs) for environment monitoring are proposed to meet extremely-long-endurance missions of nuclear power plants. The flight of the proposed tethered aerial robots may last for a few days or even a few months as long as the tethered cable provides continuous power. A high voltage AC or DC power system was newly adopted to reduce the mass of the tethered cable. The RTAR uses a tethered cable spooled from the aerial robot and an aerial tension control system. The aerial tension control system provides the appropriate tension to the tethered cable, which is accordingly laid down on the ground as the RTAR roams. The STAR includes a tethered cable spooled from the ground and a ground tension control system, which enables the STAR to reach high altitudes. Prototypes of the RTAR and STAR were designed and successfully demonstrated in outdoor environments, where the load power, power type, operating frequency, and flight attitude of the RTAR and STAR were: 180 W, AC 100 kHz, and 20 m; and 300 W, AC or DC 100 kHz, and 80 m, respectively

Multiple-Output ZVS Resonant Inverter Architecture for Flexible Induction Heating Appliances

Flexible cooking surfaces have changed the domestic induction heating product paradigm enabling the use of a wider range of cookware materials, shapes, and positions. In order to implement such systems, multiple-output resonant inverters featuring high-performance and high-efficiency operation while achieving a cost-effective implementation are required. This paper proposes a multiple-output zero-voltage-switching resonant inverter for flexible induction heating appliances. The proposed converter features a matrix structure, enabling a cost-effective implementation with a reduced number of power devices while achieving high performance and low switching losses. It has been tested by means of an experimental prototype featuring 48 induction heating coils, proving the feasibility of the proposed approach