Abstract
Wireless power transfer offers safe, convenient, and efficient way of charging electric vehicles. Ongoing research is targeting wireless charging pad design optimization; designing the magnetic component is the most important part of the coupler design because the magnetic part determines the coupling factor and efficiency. Optimizing the coil layout and geometry as well as ferrite design requires finite elements analysis based modeling and simulation for minimized core losses, maximized magnetic coupling, and minimized material use for cost-effectiveness. Although parametric finite element analysis or emerging artificial intelligence methods can generate very accurate results, simulation times are extremely long. To address this issue, this study proposes a simple, effective core design called A TOpographic Mapping (ATOM). The proposed design is based on the design of magnetic core by using the magnetic flux distribution. The thickness of the core increases with increasing magnetic flux density, forming a variable thickness core design with less material and minimized core losses compared to conventional designs. A superimposing method is used to create an optimal design for a rotational magnetic field-based system. According to simulation results, the ATOM design reduces the required material volume by 13.19% and yields the lowest core loss and highest mutual inductance compared to other designs. In addition, misalignment, electromagnetic interference, and thermal performance were evaluated for the proposed design.
| Original language | English |
|---|---|
| Pages (from-to) | 166444-166451 |
| Number of pages | 8 |
| Journal | IEEE Access |
| Volume | 13 |
| DOIs | |
| State | Published - 2025 |
Funding
This work has been funded by the Vehicle Technologies Office (VTO) and the Office of Technology Commercialization (OTC) of the U.S. Department of Energy. This manuscript has been authored by UT-Battelle LLC under contract DE-AC05-00OR22725 with the US Department of Energy (DOE). The U.S. government retains and the publisher, by accepting the article for publication, acknowledges that the U.S. government retains a nonexclusive, paid-up, irrevocable, worldwide license to publish or reproduce the published form of this manuscript, or allow others to do so, for US government purposes. DOE will provide public access to these results of federally sponsored research in accordance with the DOE Public Access Plan (http://energy.gov/downloads/doepublic-access-plan). This research used the resources available at the Power Electronics and Electric Machinery (PEEM) Laboratory at the National Transportation Research Center (NTRC), a U.S. DOE user facility operated by Oak Ridge National Laboratory (ORNL). This effort has been funded by the Vehicle Technologies Office (VTO) and the Office of Technology Commercialization (OTC) of the U.S. Department of Energy. Project partners include Volkswagen Group of America and Mitsubishi Chemicals America. The authors would like to thank Lee Slezak and Fernando Salcedo (Vehicle Technologies Office, US DOE) for funding this work and for their continuous support and guidance.
Keywords
- Core design
- electric vehicle charging
- magnetic materials
- wireless power transfer