Investigation of Thermal Effects in Different Lightweight Constructions for Vehicular Wireless Power Transfer Modules
Abstract
:1. Introduction
2. Exemplary Wireless Power Transfer System
3. Description of Proposed CPM Concepts
3.1. Sandwich Concept
3.2. Space-Frame Concept
4. Thermal Model
4.1. Calculation of Power Losses
4.1.1. Coil Losses
4.1.2. Core Losses
4.1.3. Eddy Current Losses
4.2. Thermal Simulation Model
5. Experimental Setups
5.1. Component Level Testing
5.2. System Level Testing
6. Results
6.1. Sandwich Concept
6.2. Space-Frame Concept
7. Discussion
8. Conclusions
Author Contributions
Funding
Conflicts of Interest
Abbreviations
AC | Alternating current |
CPM | Car Pad Module |
DC | Direct current |
EVs | Electric vehicles |
FE | Finite elements |
FOM | Figure-of-Merit |
GPM | Ground Pad Module |
HF | High frequency |
HiL | Hardware-in-the-Loop |
MOSFET | Metal–oxide–semiconductor field-effect transistor |
PFC | Power factor correction |
RMS | Root Mean Square |
WPTS | Wireless power transfer systems |
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Parameter | Variable | Value | Unit |
---|---|---|---|
Output Power | 11 | kW | |
GPM DC-Link Voltage | 0–540 | V | |
CPM DC-Link Voltage | 300–470 | V | |
Battery Voltage | 300–470 | V | |
Air Gap | z | 100–210 | mm |
Misalignment longitudinal | ±75 | mm | |
Misalignment transversal | ±150 | mm | |
Transmission Frequency | 81.38–90 | kHz | |
Area of CPM coil | 300 × 300 | mm2 |
Parameter | Variable | Value | Unit |
---|---|---|---|
Coil length | 600 | mm | |
300 | mm | ||
Coil width | 750 | mm | |
300 | µm | ||
Number of windings | 7 | ||
15 | |||
Self-Inductance | 77 | µH | |
112 | µH | ||
Mutual Inductance | M | 7.4–18.6 | µH |
Magnetic Coupling | k | 0.08–0.2 | |
AC-Resistance | <40 | m | |
100 | m | ||
RMS-Current | 35–100 | A RMS | |
23–36 | A RMS |
Name | Parameter | Value | Unit |
---|---|---|---|
Transmission frequency | f | 85 | kHz |
Peak coil current | 33 | A | |
Magnitude of external magnetic field | 6.62 | kA | |
Number of strands in the litz wire | N | 15 | |
Total length of litz wire | 12.7 | m | |
Outer diameter of the litz wire | 4.5 | mm | |
Specific resistance of litz wire material at 20 °C [40] | 0.018 | mm | |
Specific temperature coefficent of litz wire material at 20 °C [40] | 0.004 |
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Zimmer, S.; Helwig, M.; Lucas, P.; Winkler, A.; Modler, N. Investigation of Thermal Effects in Different Lightweight Constructions for Vehicular Wireless Power Transfer Modules. World Electr. Veh. J. 2020, 11, 67. https://doi.org/10.3390/wevj11040067
Zimmer S, Helwig M, Lucas P, Winkler A, Modler N. Investigation of Thermal Effects in Different Lightweight Constructions for Vehicular Wireless Power Transfer Modules. World Electric Vehicle Journal. 2020; 11(4):67. https://doi.org/10.3390/wevj11040067
Chicago/Turabian StyleZimmer, Steve, Martin Helwig, Peter Lucas, Anja Winkler, and Niels Modler. 2020. "Investigation of Thermal Effects in Different Lightweight Constructions for Vehicular Wireless Power Transfer Modules" World Electric Vehicle Journal 11, no. 4: 67. https://doi.org/10.3390/wevj11040067