Wireless Power Transfer For Electric Vehicle Battery Charging Miniproject

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WIRELESS POWER TRANSFER FOR ELECTRIC VEHICLE ii ii ii ii ii

BATTERY CHARGING ii

Report iisubmitted iito iithe iiSASTRA iiDeemed iito iibe iiUniversity iias iithe
requirement iifor iithe iicourse

BCHCCH706R01: iiMINI iiPROJECT-1

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iI iiiiiiiiiiiiiiiiiiiiiiiiiiiiiI iii ii ii ii
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ii
NOMENCLATURE

WPT – Wireless Power Transfer


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IPT – Inductive Power Transfer


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EV – Electric Vehicle
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SS – ii ii ii ii ii Series-Series ii

SP – ii ii ii ii ii Series-Parallel
PS – ii ii ii ii ii Parallel-Series
PP – ii ii ii ii ii Parallel-Parallel
LCL – Inductor-Capacitor-Inductor
ii ii

LCC – Inductor-Capacitor-Capacitor
ii ii

ZVS – Zero Voltage Switching


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ZCS – Zero Current Switching


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FEM – Finite Element Modelling


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HFSS – High Frequency Structure Simulator


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ii ii
i ABSTRACT

Nikola Tesla built the first system to transfer electricity over the air in 1893,
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using principles of induction discovered by Michael Faraday in the early 1800.


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Electric vehicles are becoming more popular due to ever increasing


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environmental effects and rising gasoline (petrol and diesel) prices. However,
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the disadvantage of Electric vehicle is its charging time which can be


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overcome by simple concept of Inductive Power Transfer which is an


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emerging technology for electric vehicle battery charging. IPT uses Resonance
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principle. Wireless Power Transfer is used to avoid the transmission losses and
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to save copper which will reduce the cost on economic point of view. The
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coils designed in this WPT project is strictly restricted to PERFECT


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ALIGNMENT and it does not involve MISALIGNMENTS like Planar and


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Angular misalignments.
ii ii

Specific iContribution i

• iWPT isystem ihas ibeen isimulated iin iANSYS iMAXWELL i3D iand iANSYS i i

TWIN BUILDER. i

Specific iLearning

• iWhen ithe idistance ibetween ithe itransmitter iand ireceiver icoils iis iminimum, ithe
i coefficient of coupling will be maximum which gives more efficient and
i i i i i i i i i i

i maximum power transfer. i i


INTRODUCTION
1.1 ELECTRIC VEHICLE
Electric vehicles operate on Electric motor, but other vehicles run
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iion internal combustion engine that generates power by combustion of fuel


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iiand gases. All EVs run on Electricity only. They set in motion by one or
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iimore Electric motors powered by rechargeable battery packs. So, EVs are
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iiconsidered to be a promising solution for the future transportation.


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EVs are playing an important role in long-lasting mobility with efficient


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energy utilisation and zero pollutants emission when in use. The battery has
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a great impact on the performance of the EV in determining the driving


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range. Many types of batteries are available nowadays. Among those li-ion
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batteries are most widely used because of their chemistry with good energy
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density, good power noting, and charge-discharge efficiency in pulsed


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electric flow system.


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To charge these batteries in EVs, WPT technique is adopted. WPT


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technology has been around us for decades in many applications such as


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satellite communications and radio frequency identification tags (RFID).


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The most general method of high power WPT is “Inductive Coupling” that
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was invented by Nikola Tesla more than a 100 years ago.


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i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i ii ii ii ii ii ii
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1.2 WORKING PRINCIPLE ii

Working principle of WPT ” Inductive power transfer”. This


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principle is also used in standard transformer. But contrast is that primary


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and secondary coils in transformer are so near, also uses ferrite material.
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Inductive charging system have coils which have airgap between them.
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Step by step process is given below:


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1) The supply voltage is transformed into alternating current, ideally, high


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frequency AC.
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2) This high frequency AC is carried to the coil by the way of transmitter


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circuit. Hence magnetic field is induced in transmitter coil.


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3) Due to this magnetic field, current is developed in nearby receiving coil.


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However, in the previous applications, the designers faced a


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ii problem; they observed that magnetic field reduces as distance


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ii increases; that is distance and magnetic field are inversely proportional.


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ii The decrease in magnetic strength is inversely proportional to the square


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ii of the distance from the main source. So, there is difficulty in regulating
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ii power and energy efficiency is ultimately reduced.


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1.3 RESONANCE
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To solve this problem, the designers launched resonance concept.


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ii We can calculate resonance by multiplying the capacitance of capacitor


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ii attached to the extremes of the coils with inductive coil inductance.


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Resonators of similar frequency are incorporated on both


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ii transmitter on receiver side. This guarantee that two coils are coupled
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ii in magnetic way and hence allows maximum power transfer between


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ii them and gains high efficiency too.


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This is possible only when both coils resonate at same frequency.


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At last, with the help of rectifier circuit, AC developed is transformed


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into DC for battery charging.


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This is applicable for far distances too; that is Even when coils are
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ii at far distance, by use of resonance, high power transfer can still be


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ii achieved. Thus, Perfect alignment concept can be avoided here.


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I 333#
3.4 COMPENSATION TOPOLOGIES
Compensation topologies or matching networks are critically
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ii important to rise the efficiency and reduce the VA ratings of the power
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ii electronic devices by using auxiliary inductors and capacitors to modify


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ii the reactive power.


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There are 4 basic compensation network topologies namely


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Series-Series (SS), Series-Parallel (SP), Parallel-Series (PS), and


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Parallel-Parallel (PP). Source compensation is essential for unity power


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factor pick up and to reduce source reactive power. Receiver side


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compensation improves the power transfer and efficiency. Based on the


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application required in WPT, compensated network topology is


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selected. The PP and PS compensated WPT have drawback; that is


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source coil is completely dependent on receiver coil, also power


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transfer gets lowered in case of misalignment between coils. In SP


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compensated system, advantage is that primary compensated capacitor


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is independent of mutual inductance, hence transfer high power but


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drawback is that this topology crucially rely on load variation.


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Among all four, SS compensated topology is mostly chosen has


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various advantages. In this topology, value of capacitor in both sides is


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dependent on load conditions. Also unity power factor is picked up


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under resonant conditions. Disadvantage is that, as coupling coefficient


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decreases, output power improves, this results in overcurrent in case of


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misalignment.
ii

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ii

Additionally, other compensation topologies involved are double side


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LCL, LCC, etc. In double side LCL compensation topology, for the
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transmitter side, Resonant frequency is independent on coupling coefficient


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and load conditions. But drawback is, auxiliary inductances are the same as or
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larger than those of transmitter and receiver coils, increasing cost and
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degrading the transfer frequency. So, LCC compensation topology with the
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method of tuning is used to achieve ZVS for primary inverter switches is


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adopted in our project. It has various advantages like:


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1) Resonant frequency is independent of coupling coefficient and load


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conditions.ii

2) Additional inductors used are smaller than main coils. ii ii ii ii ii ii ii

3) Output currents are independent of the load conditions (output


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voltage) and only rely on input voltage, resonant frequency, and


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mutual inductance.
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4) Constant primary current and is only calculated by input voltage, etc.


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ii

iiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiii
MOTIVATION

Wireless Power Transmission (WPT) has become one of the most ii ii ii ii ii ii ii ii ii

crucial research topic in this decade. Portability is the central motivation for
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wireless power transfer as the number of portable devices are rising rapidly
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and wired chargers will get limited.


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Our main motivation for WPT for EV battery charging is to get


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rid of increased gasoline prices, the harmful emissions caused by the gases
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into the atmosphere. Also mainly to reduce the losses that take place in wired
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power transfer (transmission losses).


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Motivations for WPT can be summarized as follows, ii ii ii ii ii ii ii

1) Increases the device mobility


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2) Avoid wiring hazards ii ii ii

3) Improves the EVs reliability


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4) Save the cost of wiring and its segregation


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5) Immune to chemicals, water and dirt


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6) Intensify the research of biomedical implementations


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7) Free of maintenance and no electrical plugs


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OBJECTIVE

In this project, the main objective is to make EVs more


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popular in the coming decades and to make an efficient WPT for EV


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battery charging. EVs should become more popular because


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nowadays car pollution is one of the major causes of global


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warming. Increasing gasoline prices are causing severe threat to


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humans. In order to mitigate pollution and gasoline usage to some


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extent, “EVs” are originated. “EVs” are an environmentally friendly


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alternative. Electric cars promise to save us money, bless all of us


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with pollution free air that eliminates harmful particles and gases and
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kickstart a transport and energy revolution. But only disadvantage is


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charging the batteries. In our project, we focused on “WPT for EV


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battery charging” which completely eliminates transmission losses


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(as no wires are used) and copper is saved. We designed simulation


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circuit of “double sided LCC compensated WPT system” which have


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various advantages than other topologies. Also ANSYS software is


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used to design transmitter and receiver coil as well as the converter


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circuit.
ii
ii ii ii ii ii ii ii ii ii ii ii I i EXPERIMENTAL WORK (SIMULATION) ii ii

3.1 MATLAB SIMULINK


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The project of WPT is divided into two parts, Simulation and


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ii Hardware setup. The Simulation is carried out by using two different


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ii software, MATLAB Simulink and ANSYS MAXWELL 3D. The


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ii MATLAB circuit is a WPT setup fed with a DC voltage source to the H


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ii – Bridge inverter made up of four MOSFET switches which converts


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ii DC to AC for the working of mutual inductor with transmitter and


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ii receiver coil for power transfer. The circuit is compensated with double
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ii side LCC topology. The double-sided inductor-capacitor-capacitor


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ii (LCC) compensated wireless power transfer (LCC-WPT) system is


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ii much energy efficient than the series-series (SS) compensated wireless


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ii power transfer for the same load as per efficiency point of view.
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ii Compensation is required because when coupling coefficient is reduced ii ii ii ii ii ii ii ii

ii to less than 0.3 in the EV WPT, compensation at both primary and


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ii secondary is compulsory to have much more tensile characteristics.


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MATLAB Circuit for WPT with double side LCC


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ii compensation
By utilizing an LCC compensation network, Zero Current
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ii Switching(ZCS) (eliminates losses due to switching and also due to ii ii ii ii ii ii ii ii ii

ii stray inductance) condition can be gained by compensation network


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ii parameters tuniand also to realize Zero Voltage Switching (turn-on


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ii transition occurs at zero voltage). ii ii ii ii ii ii ii ii ii ii ii iI i i i i i i i i i i i


i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i ii
COMPENSATION DESIGN: ii

Frequency f = 79kHz ii ii ii

1
At resonance, f =
ii ii ii ii ii ; pi=3.14
ii ii
2𝑝𝑖∗(√𝐿𝐶)

Let L = 67uH ii ii ii ii

1
ii 79 ∗ 103 =
2∗3.14∗(√67∗10−6 ∗𝐶)

We get, C = 60.6nF (parallel to mutual inductor)


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In order to get maximum efficient power transfer, the value of the second
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capacitor (in series with mutual inductor) is set in the range of nano farad,
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C = 14nF
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Coefficient of coupling (k), ii ii ii ii

𝑀 = 𝑘 ∗ √(𝐿1𝐿2) ; M = 1.85 ∗ 10−4 , L1 = L2 = 370 ∗ 10−6 ii ii ii ii ii ii ii ii ii ii

𝑀 1.85∗10−4
ii 𝑘= = = 0.5
√𝐿1𝐿2 370∗10−6

LOAD RESISTANCE DESIGN: ii ii

Considering one of the EV model – Nissan Leaf ii ii ii ii ii ii ii ii ii

MODEL BATTERY CHARGING TIME ii

Nissan Leaf ii ii 30kWh, Li-Mn, 192 ii ii 8 hours at 230 V, 15 A.


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cells, air cooled, driving


ii ii ii ii 4 hours at 230 V, 30 A.
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range up to 250km (156


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miles)
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The load resistance at output of the receiver side network can be given by,
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8
ii 𝑅 = (𝑝𝑖)2 ∗ 𝑅(𝑙𝑜𝑎𝑑)
𝑉(𝑏𝑎𝑡𝑡𝑒𝑟𝑦)
ii 𝑅(𝑙𝑜𝑎𝑑) = 𝑖𝑖 ii (equivalent load resistance of battery of electric ii ii ii ii ii ii
𝐼(𝑏𝑎𝑡𝑡𝑒𝑟𝑦)
vehicle)
ii

230
ii 𝑅(𝑙𝑜𝑎𝑑) = = 15.33 𝑜ℎ𝑚 (considering Nissan Leaf, 8hrs at 230V,15A)
𝑖𝑖 𝑖𝑖 ii ii ii ii ii
15
8
𝑅 = 15.33 ∗
ii = 12.43 𝑜ℎ𝑚 𝑖𝑖 𝑖𝑖 ii
𝑝𝑖 2
A double-sided LCC compensation network is provided for a
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wireless power transfer system. The wireless power transfer system is


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comprised generally of a send unit configured to transfer power using


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inductive power transfer and a receive unit configured to receive the power
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from the send unit. The send unit includes an inverter configured to receive a
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DC input signal and convert the DC input signal to an AC output signal at a


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desired resonant frequency; a send coil configured to receive the AC output


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signal from the inverter and generate an alternating electromagnetic field;


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and a send side compensation circuit interconnecting the inverter with the
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send coil. More specifically, the send side compensation circuit is comprised
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of a send side inductor and a send side series capacitor serially coupled
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together and coupled to a positive terminal of the send coil, as well as a send
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side parallel capacitor coupled in parallel with the send coil.


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The receive unit includes a receive coil configured to receive the


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ii alternating electromagnetic field from the send coil of the send unit and output
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ii an AC charging signal; a receive side converter configured to receive the AC


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ii charging signal from the receive coil and convert the AC charging signal to a
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ii DC charging signal; and a receive side compensation circuit interconnecting


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ii the receive coil with the receive side converter. Likewise, the receive side
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ii compensation circuit is comprised of a receive side inductor and a receive side ii ii ii ii ii ii ii ii ii ii ii ii

ii series capacitor serially coupled together and coupled to a positive terminal of


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ii the receive coil, as well as a receive side parallel capacitor coupled parallelly
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ii with that of receive coil. ii ii ii ii ii

On the output side, the four diodes arrangement with capacitor and
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ii resistor form the Bridge Rectifier and Filter to remove the ripples and
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ii rectifier converts AC to DC required for the charging of the battery of


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ii EV. This supplies direct current to the load. In this way, electrical
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ii energy is shifted through air from the transmitter to the receiver coils.
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The input and output power are measured in the circuit simulation
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ii and the efficiency is also calculated for maximum wireless power transfer.
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3.2 ANSYS MAXWELL 3D COIL DESIGN
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Ansys is a Finite Element Modelling (FEM) simulation tool, the


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ii WPT coils can also be designed using HFSS (high frequency structure
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ii simulator), COMSOL for accurate calculation of mutual inductance.


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In the above MATLAB circuit we used mutual inductor for


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power transfer, but now we will replace the mutual inductor with 3D coil
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designed using ANSYS MAXWELL software. The coils designed in ANSYS


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are of polygon helix shape and consists of two coils separated by a small
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distance in mm. One is known as the transmitter coil and the other is known
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as the receiver coil. Each polygon segment of the coil is circular.


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ANSYS WPT COIL ii ii

Both the transmitter and receiver coils have equal number of turns
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iibut their polygon radius will differ. The receiver coil will have smaller
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iipolygon radius than the transmitter coil because the receiver is in the
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iivehicle, so it should be small and the receiver is to be fixed within the


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iivehicle. Now, the terminals of the coils are given an excitation and
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iiparameters such as analysis, mesh operations, etc are setup and a


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iitabulation called magnetisation report is created which will be filled


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with coefficient of coupling, self and mutual inductance values once the
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simulation is started.
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The distance between the coils is initially set as 6mm and the
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iterations are given before the starting of the simulation so that we can
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get the values for various distances between the transmitter and receiver
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coils.
ii

If the distance between the coils is set in the range of mm,


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ii the simulation will take nearly 8-10 hours to complete. If it is kept in


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ii cm, it will take a couple of days to show the result.


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3.3 ANSYS TWIN BUILDER CONVERTER DESIGN


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ANSYS software has many features in which TWIN


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ii BUILDER is one and it is very much similar to our MATLAB


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ii SIMULINK because it has all the power electronic devices, all the
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ii sources, all active and passive elements, etc.


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The circuit which was constructed in MATLAB SIMULINK


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ii is reconstructed in ANSYS TWIN BUILDER with the similar power


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ii electronic devices, but the only difference is that the mutual inductor is
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ii replaced by the coil which was designed in ANSYS MAXWELL 3D


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ii and it is given as an input to the converter for the wireless power


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ii transfer.

ii ii ii ii ANSYS WPT CONVERTER ii ii

ii ii ii ii ii ii ii
ii ii ii ii ii ii ii ii ii ii ii ii ii ii ii ii ii ii ii ii ii ii ii ii ii ii ii ii ii ii ii ii

i i i i i i i ii RESULTS AND DISCUSSIONS ii ii

4.1 MATLAB SIMULINK WAVEFORMS


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After the MATLAB simulation is done, we will get the values of ii ii ii ii ii ii ii ii ii ii ii

input and output power through which we can calculate the efficiency of
ii ii ii ii ii ii ii ii ii ii ii ii

power transfer.
ii ii

Input power ii 8680 W ii

Output power ii 8397 W ii

Efficiency ii 96.74 % ii

INPUT POWER WAVEFORM IN MATLAB SIMULINK


ii ii ii ii ii
OUTPUT POWER WAVEFORM IN MATLAB SIMULINK
ii ii ii ii ii

ANSYS MAXWELL 3D COIL SIMULATION TABULATION


ii ii ii ii ii

ii ii ii ii ii ii ii ii ii ii ii ii ii ii ii ii
CONCLUSION AND WORK

Even though wired charging is popular, problems with tangled ii ii ii ii ii ii ii ii

wires and their behaviour concerns in wet environment are major drawback of
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EVs. These problems can be controlled by battery charging of the vehicle


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without wires and this technology is termed as WPT. In our project, we


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developed “WPT” technology and choose best “LCC” topology among all
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other topologies to design. Simulation circuit and got superior results with
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high efficiency. Also by using ANSYS software, coil and converters are
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designed. Finally, our project aims for the efficient WPT of EV battery
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charging, which might be very useful for humans and stands for future use as
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well.
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As one part of the project is completed which is the simulation


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part and got the efficient results with maximum power transfer. Further work
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is the second part of the project which is the hardware part in which we will
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practically prove WPT by using two copper coils as transmitter and receiver
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and various other power electronic devices are arranged in an orderly manner.
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REFERENCES
❖ D. Kishan and P. S. R. Nayak, "Wireless power transfer technologies for
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❖ S. Zhou, S. Dong, C. Zhu, C. C. Chan, S. Cui and L. Zheng, "A Simplified
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❖ J. Shin et al., "Design and Implementation of Shaped Magnetic-Resonance-
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❖ G. A. Covic and J. T. Boys, "Modern Trends in Inductive Power Transfer for
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10.1109/JESTPE.2013.2264473.
❖ Q. Zhu, L. Wang, Y. Guo, C. Liao and F. Li, "Applying LCC Compensation
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10.1109/TIE.2016.2529561.
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10.1109/JPROC.2013.2244536.
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