Thermal Design and Optimization of High- Power Wireless Charging System

Mostak Mohammad; Omer C. Onar; Veda P. Galigekere; Gui Jia Su; Jonathan Wilkins

doi:10.1109/APEC43599.2022.9773484

Thermal Design and Optimization of High- Power Wireless Charging System

Mostak Mohammad, Omer C. Onar, Veda P. Galigekere, Gui Jia Su, Jonathan Wilkins

Research output: Contribution to conference › Paper › peer-review

8 Scopus citations

Abstract

In this paper, the thermal design and optimization of a high-power wireless charging system (WCS) is proposed. An integrated electromagnetic and thermal co-optimization is essential to design a high power-density WCS pad. This study presents the thermal analysis and the potential optimization scopes for a polyphase WCS pad. The coil and core causes most of the power losses of a WCS pad and causes thermal hotspot in the pad. In this paper, the thermally conductive epoxy is introduced to balance the effective volumetric loss density in the pad and mitigate the thermal hotspots in the coil and core. The proposed design is simulated through finite element analysis (FEA) and tested experimentally for a 50 kW three-phase WCS. Simulation and experimental results show that the conventional design has localized hotspots in the coil and core. The proposed thermal design mitigates the thermal hotspots without increasing the coil or core volume.

Original language	English
Pages	480-485
Number of pages	6
DOIs	https://doi.org/10.1109/APEC43599.2022.9773484
State	Published - 2022
Event	37th Annual IEEE Applied Power Electronics Conference and Exposition, APEC 2022 - Houston, United States Duration: Mar 20 2022 → Mar 24 2022

Conference

Conference	37th Annual IEEE Applied Power Electronics Conference and Exposition, APEC 2022
Country/Territory	United States
City	Houston
Period	03/20/22 → 03/24/22

Funding

The authors would like to thank Dr. Burak Ozpineci (ORNL) and Lee Slezak (U.S. Department of Energy) for their support and guidance of this work. This manuscript has been authored by Oak Ridge National Laboratory, operated by UT-Battelle, LLC, under Contract No. DE-AC05-00OR22725 with the U.S. Department of Energy. The United States Government retains and the publisher, by accepting the article for publication, acknowledges that the United States Government retains a non-exclusive, paid-up, irrevocable, world-wide license to publish or reproduce the published form of this manuscript, or allow others to do so, for United States Government purposes. The Department of Energy will provide public access to these results of federally sponsored research in accordance with the DOE Public Access Plan (http://energy.gov/downloads/doe-public-access-plan).

Keywords

Inductive charging
electric vehicle
thermal design

Access to Document

10.1109/APEC43599.2022.9773484

Cite this

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title = "Thermal Design and Optimization of High- Power Wireless Charging System",

abstract = "In this paper, the thermal design and optimization of a high-power wireless charging system (WCS) is proposed. An integrated electromagnetic and thermal co-optimization is essential to design a high power-density WCS pad. This study presents the thermal analysis and the potential optimization scopes for a polyphase WCS pad. The coil and core causes most of the power losses of a WCS pad and causes thermal hotspot in the pad. In this paper, the thermally conductive epoxy is introduced to balance the effective volumetric loss density in the pad and mitigate the thermal hotspots in the coil and core. The proposed design is simulated through finite element analysis (FEA) and tested experimentally for a 50 kW three-phase WCS. Simulation and experimental results show that the conventional design has localized hotspots in the coil and core. The proposed thermal design mitigates the thermal hotspots without increasing the coil or core volume.",

keywords = "Inductive charging, electric vehicle, thermal design",

author = "Mostak Mohammad and Onar, {Omer C.} and Galigekere, {Veda P.} and Su, {Gui Jia} and Jonathan Wilkins",

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AU - Mohammad, Mostak

AU - Onar, Omer C.

AU - Galigekere, Veda P.

AU - Su, Gui Jia

AU - Wilkins, Jonathan

PY - 2022

Y1 - 2022

N2 - In this paper, the thermal design and optimization of a high-power wireless charging system (WCS) is proposed. An integrated electromagnetic and thermal co-optimization is essential to design a high power-density WCS pad. This study presents the thermal analysis and the potential optimization scopes for a polyphase WCS pad. The coil and core causes most of the power losses of a WCS pad and causes thermal hotspot in the pad. In this paper, the thermally conductive epoxy is introduced to balance the effective volumetric loss density in the pad and mitigate the thermal hotspots in the coil and core. The proposed design is simulated through finite element analysis (FEA) and tested experimentally for a 50 kW three-phase WCS. Simulation and experimental results show that the conventional design has localized hotspots in the coil and core. The proposed thermal design mitigates the thermal hotspots without increasing the coil or core volume.

AB - In this paper, the thermal design and optimization of a high-power wireless charging system (WCS) is proposed. An integrated electromagnetic and thermal co-optimization is essential to design a high power-density WCS pad. This study presents the thermal analysis and the potential optimization scopes for a polyphase WCS pad. The coil and core causes most of the power losses of a WCS pad and causes thermal hotspot in the pad. In this paper, the thermally conductive epoxy is introduced to balance the effective volumetric loss density in the pad and mitigate the thermal hotspots in the coil and core. The proposed design is simulated through finite element analysis (FEA) and tested experimentally for a 50 kW three-phase WCS. Simulation and experimental results show that the conventional design has localized hotspots in the coil and core. The proposed thermal design mitigates the thermal hotspots without increasing the coil or core volume.

KW - Inductive charging

KW - electric vehicle

KW - thermal design

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Thermal Design and Optimization of High- Power Wireless Charging System

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