High-Power Polyphase PCB-Type Inductive Coupler for Wireless Electric Vehicle Charging

Donovin D. Lewis, Omer Onar, Lucas Gastineau, John F. Eastham, Dan M. Ionel

Research output: Chapter in Book/Report/Conference proceedingConference contributionpeer-review

Abstract

The cost and manufacturing difficulty of traditionally wound coils for wireless charging of electric vehicles has led to the exploration of alternative manufacturing for scalable deployment at a range of rated powers. A rotating-field polyphase wireless coupler is developed with balanced fully pitched coils which are not possible with conventional Litz wire. The usage of printed circuit board (PCB) technology is proposed for the innovative construction at large dimensions due to reduced cost, increased ease of manufacturability, and potential geometric customization compared to would coils. Design considerations specific to PCBs are detailed for wireless power transfer coils including advantages such as the potential for many turns and transposition with planar interconnections. A design procedure is developed which may be used to investigate the frequency to power to dimension correlation and limits associated with PCB coils. Designs are simulated in 3D electromagnetic finite element analysis (FEA) for the polyphase coil to evaluate the coupling between coils with varying geometric parameters at 100mm and 500mm outer diameters. A discussion is included on methods to increase PCB power ratings through a mixture of layer stacking, connections, and material selection.

Original languageEnglish
Title of host publication2024 IEEE Transportation Electrification Conference and Expo, ITEC 2024
PublisherInstitute of Electrical and Electronics Engineers Inc.
ISBN (Electronic)9798350317664
DOIs
StatePublished - 2024
Event2024 IEEE Transportation Electrification Conference and Expo, ITEC 2024 - Chicago, United States
Duration: Jun 19 2024Jun 21 2024

Publication series

Name2024 IEEE Transportation Electrification Conference and Expo, ITEC 2024

Conference

Conference2024 IEEE Transportation Electrification Conference and Expo, ITEC 2024
Country/TerritoryUnited States
CityChicago
Period06/19/2406/21/24

Keywords

  • Electric vehicle (EV)
  • planar coil
  • printed circuit board
  • scalability
  • wireless charging
  • Wireless power transfer

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