New design of high-power in-motion inductive charger for low power pulsation

Ahmed A Shaier; Ahmed A S Mohamed; Hamid Metwally; Sameh I Selem

doi:10.1038/s41598-023-44949-z

New design of high-power in-motion inductive charger for low power pulsation

Sci Rep. 2023 Oct 19;13(1):17838. doi: 10.1038/s41598-023-44949-z.

Authors

Ahmed A Shaier¹, Ahmed A S Mohamed², Hamid Metwally¹, Sameh I Selem³

Affiliations

¹ Electrical Power and Machines Department, Faculty of Engineering, Zagazig University, Zagazig, Egypt.
² Eaton Research Labs, Eaton Corporate, Golden, CO, USA.
³ Electrical Power and Machines Department, Faculty of Engineering, Zagazig University, Zagazig, Egypt. sameh.eb@gmail.com.

Abstract

The magnetic coupler is the most vital component for charging EV wirelessly. Through it, the output power can be transported from the transmitter to the receiver by means of electromagnetic fields. Therefore, this manuscript presents a proposed design of a magnetic coupler in the form of Double-D (DD) on both sides, which is suitable for in-motion inductive charging. This charger is capable of transferring power of 200-kW through an airgap of 250 mm with an efficiency of 91.88% and an operating frequency of 85 kHz. Computational modeling is conducted to obtain the magnetic coupler and the compensation parameters of the proposed system. The appropriate dimensions of the coils, magnetic and metallic shielding are obtained by using the finite element model (FEM). The effect of misalignments on the self and mutual inductances of the two coils (L_p, L_s, M), the output power (P_o), and the transmission efficiency (η) is studied in case of one and two coils at transmitter side. The output power in the distance between the two transmitter coils (d) is improved by controlling the operating frequency, adding magnetizable concrete (MC), or both together. These techniques have proven effectiveness in improving the output power by 45.15% for small d and 72.51% for large d. In addition, the efficiency improved by 15.95% for small d and 60.76% for large d. Moreover, these improvement cases were compared in terms of size, weight and cost for a 100-m driving track.