Modeling of Inductive Contactless Energy Transfer Systems

In the domain of electronic devices and especially desktop peripherals, there is an industrial trend which consists in removing the cables that pollute our domestic and professional environments. In this sense, wireless communication protocols are already massively widespread while the power supplies still use wires or batteries. To address this problem, alternative solutions must be investigated such as contactless energy transfer (CET). In a broad sense, CET is a process that allows to bring electrical energy from one point to another through a given medium (generally air or vacuum) and at a certain distance. Inductive CET means that the intermediate form of energy is the magnetic induction, generated from primary coils excited by high-frequency alternating currents and collected in secondary coils by induced voltages. Most of existing approaches to design CET systems are applicable to only single applications and do not include an optimization method. For this reason, the present thesis focuses on the modeling, design and optimization of inductive CET systems. Using the coreless transformer as the central part of CET systems, an equivalent electric model is derived from the theory of conventional transformers. The absence of ferrite core gives rise to a specific characteristic, which is to have large leakage inductances compared to the main one. In order to circumvent this issue, using a high frequency together with a resonant circuit allow to enhance the effect of the mutual inductance and to transfer power with an excellent efficiency. Different parts of the coreless transformer are addressed separately. First, an accurate modeling of DC resistances, self and mutual inductances is proposed. Then, the equivalent electric circuit is resolved and the different compensation topologies for the resonant circuit are discussed. Finally, the AC resistance is computed using a 2D finite element modeling that takes into account the skin and proximity effects in the conductors. So as to exploit optimally FEM simulations, a complete output mapping together with a specific interpolation strategy are implemented, giving access to the AC resistance evaluation in a very short time. As a result, all the models are implemented in a way that makes them highly adaptable and low-consuming in term of computing resources. Then a sensitivity analyzis is performed in order to restrict the variation range of different parameters and to provide a general and intuitive understanding of inductive CET. After that, an optimization method using genetic algorithms (GAs) is presented. The main advantage of GAs is that the number of free parameters does not change the complexity of the algorithm. They are very efficient when a lot of free parameters are involved and for optimizations where the computing time is a key factor. As existing GAs failed to converge properly for different tested CET problems, a new one is developed, that allows to optimize two objective functions in the same time. It is thus a multiobjective genetic algorithm (MOGA) and has been successfully applied to the design of different CET systems. Finally, in order to validate the models and optimization methods proposed along the thesis, several prototypes are built, measured and tested. Notably, a CET table that allows to supply simultaneously different peripherals is fabricated. By analyzing in real time the current amplitude in the primary coils, an efficient sensorless detection of the peripherals is implemented. Digital control techniques have enabled the autonomous management of the detection and the local activation of the table. These results contribute to the future development of robust and efficient CET tables

Wireless Low-Power Transfer for Galvanically Isolated High-Voltage Applications

For various applications, such as gate drivers for transistors, wireless chargers for mobile devices and cars, and isolated measurement equipment, an isolated DC power supply for electronic components is required. In this work, a new concept for an isolated power supply with insulation strength of 50 kV and power transmission of up to 60 W to supply measurement equipment with 12 or 24 V is presented. Furthermore, high overall efficiency of 82.5% at 55 W is achieved. Feasibility is demonstrated in a real application powering data acquisition electronics at high reference potential. Our new concept uses a coreless printed circuit board (PCB) transformer (15 cm × 10 cm × 4 cm and a weight of 480 g) designed for maximum efficiency via a coil layout and close proximity of adjacent coils on one PCB while reaching high isolation strength via the PCB material and potted coils. To increase efficiency, we investigated different coil geometries at different frequencies. A low-cost design consisting of two Qi charging coils mounted on one PCB is compared with our integrated PCB transformers manufactured from a four-layer PCB with ferrites applied on the outside. With this new design, high isolation voltages are possible while reaching high transformer efficiency of up to 90%. © 2022 by the authors. Licensee MDPI, Basel, Switzerland

Micro air vehicles energy transportation for a wireless power transfer system

The aim of this work is to demonstrate the feasibility use of an Micro air vehicles (MAV) in order to power wirelessly an electric system, for example, a sensor network, using low-cost and open-source elements. To achieve this objective, an inductive system has been modelled and validated to power wirelessly a sensor node using a Crazyflie 2.0 as MAV. The design of the inductive system must be small and light enough to fulfil the requirements of the Crazyflie. An inductive model based on two resonant coils is presented. Several coils are defined to be tested using the most suitable resonant configuration. Measurements are performed to validate the model and to select the most suitable coil. While attempting to minimize the weight at transmitter’s side, on the receiver side it is intended to efficiently acquire and manage the power obtained from the transmitter. In order to prove its feasibility, a temperature sensor node is used as demonstrator. The experiment results show successfully energy transportation by MAV, and wireless power transfer for the resonant configuration, being able to completely charge the node battery and to power the temperature sensor.Peer ReviewedPostprint (published version

Review on stationary CPT technologies and coil designs for EVs

In the recent decade, the driving range of pure EVs with zero emission target has become a popular topic as the massive battery requirement for longer distance travels means higher vehicle cost and longer time of recharging periods. Stationary CPT charging solutions could be an alternative to reduce EVs weight, size and energy storage unit costs. Fortunately, with progressive success of low-power CPT charging applications proposed to be commercially produced in the past decade, hundreds of kilowatts level high-power CPT charging techniques for EVs are more and more expected to be an optimally suitable solution for recharging EV batteries, providing higher propulsion and delivering continuously longer driving range in the next generations of the EVs. The idea of deploying inductive coupling for EVs has acquired a lot of attentions in the last decade due to the contributions and advancements of power electronics, switching power supply, semiconductors, microprocessors, electrochemistry, material sciences, control technologies, electromagnetics and so on, despite many challenges to be addressed including EV manufacturing integration with CPT system under the chassis, infrastructure difficulties, system maintenance on both vehicle and transmitting ground sides, actual CPT performance with real-time coupling on real-world road. In order to ensure the realization and enhance the sustainability in transportation sector with the emerging CPT ideas, currently the stationary CPT charging solutions based on inductive power transfer (IPT) have been developed from laboratory level as a first step to the practical tests of commercial realizations. In a few industrial fields nowadays, some of the proposed CPT technologies with specific coupler coil designs have been expected for real-world applications. This article presents a state of the art of the CPT technologies and focuses on reviewing current coil designs for high-power contactless energy transfer for EVs in the literature

Low-cost online contact resistance measurement of power connectors to ease predictive maintenance

© 2019 IEEE. Personal use of this material is permitted. Permission from IEEE must be obtained for all other uses, in any current or future media, including reprinting /republishing this material for advertising or promotional purposes, creating new collective works, for resale or redistribution to servers or lists, or reuse of any copyrighted component of this work in other worksWith the increasing use of sensors and wireless communication systems, predictive maintenance is acquiring more and more importance to assess the condition of in-service equipment. Predictive maintenance presents promising cost savings, as it allows minimizing unscheduled power systems faults, which can have very costly and catastrophic consequences. Early stage detection of power system failure requires acquiring, monitoring, and periodically analyzing the condition of the elements involved, such as high-voltage power connectors, since they are critical devices which are often located in key points of power systems. This paper proposes a low-cost online system to determine the contact resistance of high-voltage direct current (dc) and alternating current (ac) power connectors, to determine their health condition in order to apply a predictive maintenance plan. The contact resistance is considered as a reliable indicator of the connector's health condition. However, it cannot be directly measured, and the applied strategy differs between dc and ac power systems. The experimental results show a maximum uncertainty of 4.5%, thus proving the accuracy and feasibility of the approach presented in this paper, since the proposed limit of acceptable resistance increase is 20%. This approach can also be applied to many other power systems' elements.Postprint (author's final draft

Electric Power Systems and Components for Electric Aircraft

Electric aircraft have gained increasing attention in recent years due to their potential for environmental and economic benefits over conventional airplanes. In order to offer competitive flight times and payload capabilities, electric aircraft power systems (EAPS) must exhibit extremely high efficiencies and power densities. While advancements in enabling technologies have progressed the development of high performance EAPS, further research is required. One challenge in the design of EAPS is determining the best topology to be employed. This work proposes a new graph theory based method for the optimal design of EAPS. This method takes into account data surveyed from a large set of references on commonly seen components including electric machines, power electronics and jet engines. Thousands of design candidates are analyzed based on performance metrics such as end-to-end system efficiency, overall mass, and survivability. It is also shown that sensitivity analysis may be used to systematically evaluate the impact of components and their parameters on various aspects of the architecture design. Once an EAPS architecture has been selected, further, detailed, validation of the power system is required. In these EAPS, many subsystems exist with timescales varying from minutes to hours when considering the aerodynamics, to nanosecond dynamics in the power electronics. This dissertation presents a multiphysics co-simulation framework for the evaluation of EAPS with a unique decoupling method to reduce simulation time without sacrificing detail. The framework has been exemplified on a case study of a 500kW all-electric aircraft, including models for aerodynamics, energy storage, electric motors and power electronics. Electric machines for aviation propulsion must meet several performance requirements, including a constant power speed range (CPSR) of approximately thirty percent above rated speed. This operation is traditionally achieved through the flux weakening technique with an injection of negative d-axis current. However, the degree of CPSR achievable through flux weakening is a strong function of the back emf and d-axis inductance. This dissertation reviews alternative methods for CPSR operation in machines with low inductance. A new method of current weakening has been proposed to address this challenge, involving reducing the machine\u27s current inversely proportional to the operating speed, maintaining constant power through the extended speed range. One benefit of the proposed method is that all current is maintained in the q-axis, maintaining maximum torque per ampere operation. Coreless axial flux permanent magnet (AFPM) machines have recently gained significant attention due to their specific form factor, potentially higher power density and lower losses. Coreless machine designs promise high efficiency particularly at higher speeds, due to the absence of a ferromagnetic core. In this dissertation, coreless AFPM machines with PCB stators are investigated as candidates for propulsion in electric aircraft applications. Two PCB stator design variations are presented with both simulation and experimental results

Development of an Air Coil Superconducting Fault Current Limiter

Electrical power grids are the lifeline of technical infrastructure and fundamental for industry and modern lives. Fault Currents can disrupt the continuous supply of electrical energy, cause instable grid conditions and damage electrical equipment. The Air Coil Superconducting Fault Current Limiter (AC-SFCL) is a measure to effectively limit fault currents. The concept is investigated and proven experimentally by designing, building and successfully testing a 60 kV, 400 V, z = 6% demonstrator

Detection and evaluation of damage in aircraft composites using electromagnetically coupled inductors

The paper presents a quantitative damage evaluation of carbon-fibre reinforced polymer (CFRP) plates using a non-contact electromagnetic (EM) sensor. The EM sensor with coupled spiral inductors (CSI) is employed here to detect both impact induced and simulated damage leading to an accurate evaluation of the location, depth and width of sub-surface defects. The effect of inspection frequency, standoff distance and signal power are also investigated leading to the development of an engineering circuit design tool that relates the set up and calibration of the sensor to its detection performance. It is found that the dynamic range of the transmission coefficient is the limiting factor in the original Salski CSI sensor and this problem is addressed by adding ferrite layers to reduce the reluctance of the magnetic circuit, improving damage sensing by 22%. The study leads to a further development of utilising an open ferrite yoke with a pair of encircling coils, which shows a 57% sensitivity improvement and clearer identification of air gaps (voids) and delamination in CFRP laminates. The proposed EM yoke design CSI sensor is low cost and could be assembled into an array for non-contact, in situ mechatronic scanning of aircraft composite wings