High-power inductive power transfer transfer system

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High-power inductive power transfer transfer system

Context

Prodrive Technologies is a developer and manufacturer of world-class electronics. It comprises over 1300 employees and is one of the fastest growing companies in Europe. Our organization is mostly based on two groups: Development and Operations. The Development department is oriented at developing first-class electronic, mechanic and software solutions. The operations department is responsible for production, assembly, testing and life-cycle-management of electronic products and systems in the range of 1 to more than a million pieces per year.

Inductive (wireless) power transfer (IPT) systems are widely discussed for the automated charging of electric vehicles. Simultaneously, standards such as the SAE Recommended Practice J2954 are being developed in order to define acceptable criteria for interoperability, electromagnetic compatibility, minimum performance, safety and testing of such systems. However, enabling wireless charging at power levels up to 11 kW while meeting all these criteria is posing a tremendous challenge on the design and optimization of the power electronics and resonators, especially given the constraints (e.g. thermal) and inherent position-dependent tolerances on components.

Assignment

Goal/objective

The goal of the assignment is to analyze the topological (power electronics and resonators) implementations of the wireless (inductive) power transfer systems provided in the SAE J2954, to select the ‘highest potential’ (regarding efficiency and volume) candidate topology, and to investigate the feasibility (regarding meeting the SAE J2954 criteria and other given system constraints) of this topology for 11 kW (WPT3) charging at height range of 100mm – 160mm.

Approach

Starting from a specific set of requirements (input/output voltage/current conditions, power level, EMC limits, etc.), one ‘highest-potential’ IPT topology will be selected out of the SAE J2954. Thereafter, an appropriate modulation scheme will be derived and a component dimensioning and optimization will be performed, given a set of system constraints (e.g. thermal), design criteria (such as defined in the SAE J2954; e.g. frequency of 85 kHz), etc. This requires the development of models for component losses and volume, as well and overall optimization algorithms/routines. Measurement data from previously built resonator setups are available as input for these models. The ‘optimal’ solution that is found needs to be verified using a hardware prototype that will be designed, built, and tested.

Methods

  • Understanding (and synthesis) of inductor power transfer topologies (power electronics + resonator)
  • Frequency-domain (state-space) converter modeling
  • Derivation of an appropriate modulation scheme
  • Detailed loss and volume models of the main converter components (given input data of previous resonator designs)
  • Multi-objective optimization
  • Closed-loop control (support of control engineer will be provided)
  • Hardware design and testing (support of mechanical & PCB engineer will be provided; existing hardware can be reused)

Deliverables

  • Answer to the question if the topological (power electronics and resonator) implementation of the ‘highest potential’ inductive power transfer system provided in the SAE J2954 is feasibility for 11 kW (WPT3) charging at a height range of 100mm – 160mm.
  • Answer to the question what the optimal implementation for such system, and what the optimal achievable performance (in terms of efficiency and volume) are, given the criteria of the standard, the system constraints imposed (e.g. thermal), and the variation of the component values (depending on the position).
  • Working hardware prototype to verify the models and performance prediction.
  • Report (paper format is acceptable)

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