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Possibilities in Inductive Energy Transfer

Grant Covic, John Boys


Power Electronics Research Department of Electrical & Computer Engineering The University of Auckland

Overview:

Motivation IPT Concepts State of the Art IPT Research Challenges

Motivation:

Wireless Power

Motivation:
Added Value:
Wireless Data

IPT Concepts

IPT Systems:

Supply Current sourced


Independent secondaries Efficiency high under load (0 at no load)

Secondary can move


Tuned Pickup
SwitchedMode Controller DC
power

3 Input

L2 Power Supply

Pickup Inductance

track conductor inductance = L1

I1

IPT Concepts:

k=

M L1L2

Loosely coupled
Individual k very low < 0.05

Closely coupled
Transformer Induction Motor
k typically > 0.98

Primary recessed in floor: flat pick-ups

Rail mounted: E-core

Tuned Pickup

SwitchedMode Controller

DC power 3 Input

L2

Pickup Inductance

Tuning:

Power Supply

track conductor inductance = L1

I1

Primary: Reduce Supply VA Rating


Long Track: Series Concentrated Coil: Parallel

Secondary: Improve Power Transfer


Current Source: Parallel Voc Voltage Source: Series
Series (QIsc)

Pout = Voc I sc Q

none

Parallel (QVoc)

Isc

Parts of an IPT System:

Non-permeable Track Guide (Aluminium or Plastic)

Pick-up Coil Ferrite

Plastic Supports Track Conductors

UOA: Materials Handling using E pick-up

The Quest for More Power:


Increase the track frequency Increase the track current Increase M or reduce L2

Increase Q
2 M 2 P = Voc I scQ = I 1 Q L2

Electronic Decoupling Controller:


LDC

I1 M

L2
S

C DC

M P= I 1 Vo (1 D) L2 2 2

State of the Art Systems

The Present State of the Art:


Automotive applications Clean Factory Automation People moving Battery Charging Traffic Control Power transfer Applications

Automotive: Monorails & AGVs


100m Sections 10 trolleys @ 750W

AGV 3kW Batteries V 30mm L +/- 30mm

Daifuku & Wampfler

Automotive: Skillet

Daifuku

Automotive: Hoists & AGVs

Daifuku

Clean Factory Automation:

Daifuku: Clean Room Systems

Automotive:

Japan Public Works Research Institute Test Track for new road pavements 1 vehicle 90 kW power 165 m track length Vehicle weight 22 tonne Speed 30 km/h

10kW Pickup

Wampfler: Rail Applications

Sorting:

Paris (Carrefour), Turin, London

4 x 1.5 kW Power (75 or 48Vdc) Track Length ~ 210 - 280 m

Wampfler: Rail Applications

People Moving:

EXPO 2000, Hanover, Germany Hermes Tower Outdoor Elevator

3 kW power transfer for cabin lights, doors, ventilation window heating, communications Track length ~ 65 m

Wampfler: Rail Applications

Automotive:

BMW, Germany Floor Conveying System

15 vehicles 6.6 kW each Track length ~75 m

Wampfler: Rail Applications

Automotive: Floor Conveying System Engine Assembly Line


58 vehicles 1.5 kW per vehicle for drive, lift and swivel motors Track length ~ 2 x 180m

AUDI, Germany:

Wampfler: Rail Applications

Automotive:

BMW, Germany:
Floor Conveying System Engine Assembly Line

35 vehicles each requiring 1.5 kW Track length ~ 150 m

Wampfler: Rail Applications

People Moving:

Wampfler: Charging- discontinuous power transfer

People Moving:

Whakarewarewa People Mover, Rotorua, New Zealand

5 buses with trailer 3 x 10 batteries of 12 V Charging: 7min /15-20 min Charging power: 20 kW

Wampfler: Charging flat pick-ups

People Moving:

Whakarewarewa Rotorua

Power supply
Modified AC inverter

Charging bays
Rapid charging Computer controlled

Wampfler: 20kW charging stations

People Moving:

Genoa, Porto Antico

3 buses each with 56 x 6V Batteries Charging 60kW for 10 minutes/hour

Wampfler: Charging flat pick-ups

State of the Art:

Weil-am-Rhein

Pickups Primary Coils

Energy Supply (Current) Cooling System (Water)

Wampfler: 60kw Charging station

State of the Art:


Lowering Mechanism for Pickup Supporting Frame for Pickup
M

Genoa, Porto Antico

30 mm (max)

Wampfler: Charging

Traffic Control:

Wellington Tunnel Illinois, USA


Roadway lighting 2km/ 2kW 1 Stud/10m @ 2W 38.4kHz at 16A

Pedestrian Crossings 200W 20 Studs Slow Comms (1kb/s) (FM Modulation)

Hardings: Road studs with flat pick-ups

IPT Research Programs

IPT Research: Wish List


Low System Cost Primary Supply


Minimum VA rating Stable power transfer Drive long track lengths Load shedding for peak power

Movable Pickups
Low Size & Weight Excellent Magnetic Coupling Self tuning

Communications
Low Cost/High Bandwidth

IPT Research: Major Programs


Electromagnetic design Roadway systems Power regulators Communications Power supplies Power scheduling Harmonics and standards Transient behaviour

Electromagnetic Design

Pick-up Design: Experimental


la

52mm lg Litz Cable


30.00

M2 P = I Q L2
2 1

MAOP at h=52mm (VA)

Power 1/80 Scale 72% of final frequency Estimation required for final system

th

d off-centre

MAOP la=86 25.00 MAOP la=120 MAOP la=155 20.00 MAOP la=190 MAOP la=230 15.00

10.00

5.00

0.00 0 20 40 60 80 100 120 140 160 Distance off centre (mm)

Pick-up Design: FEM Analysis


49.5mm 3mm 18mm 21mm 49.5mm

FEM Analysis: Gaps & Multiple Pick-ups


Impacts of Air Gaps
Air gap size (mm)

Track
Leakage flux

Track Constructive Mutual Coupling

Destructive Mutual Coupling

FEM Analysis: Ferrite Positioning

Roadway Systems

Roadway Systems: Single Phase


Traditional Single phase Flat Pick-ups

10

10

Uncompensated Power [Su]

Uncompensated Power [Su]

0 -150 -100 -50 0 50 100 150

0 -150 -100 -50 0 50 100 150 Distance from Track Centre (mm)

Distance fromTrack Centre (mm)

Su = Voc I sc

Flat-E

Simple Flat

Roadway Systems: Multiphase


3 LCL Resonant Converter & Open-Delta Track
LCL Network DC Input 3-phase inverter LCL Network LCL Network A+ CB+ AC+ B-

A+ CBC+ AA+ C-

Ferrite

B+

B+

A-

C+

B-

Roadway Systems: Comparisons


Three Phase vs. Single Phase
12 10 8 6 4 2 0 -150 -100 -50 0 50 Distance from Track Centre 100 150 Three Phase Open Delta Single Phase Uncompensated Power [Su]

Su = Voc I sc

Simple Flat 40A/phase at 38.4kHz 3 wire spacing 40mm 1 wire spacing 100mm

Power Regulators

Tuned Pickup

SwitchedMode Controller DC power

Power Regulators:
V0 L3 D
+

3 Input

L2 Power Supply

Pickup Inductance

track conductor inductance = L1

I1

I1
M

L2 C2 S C3

Voc

" f RESONANT " >>" f CONTROL " >>" f OUT "

Resonant poles

Control pole

Output pole

Active Tuning:
Variable VAR Device Pick-up Controllers

M2 Q P = I L2
2 1

Maintaining resonance with high Q Re-tuning for magnetically enhanced tracks


Power Supply & Track Tuning

IPT Communications

An Ideal IPT Comms System:


Low-cost Non-contacting Maintenance free High data rate > 8.7 MB/s Bolt-on system Long range Isolation between IPT systems

300 Ohm ribbon & Antenna Mounting:

0 0 -5 2 4 6 8 10 12 14

Signal received (dBm)

-10

300MHz: Pin 0dBm


-15

-20 y = -0.222x - 24.692 -25

-30

-35

Distance along track (m)

Conclusions and Challenges


Specific Systems engineered for


Monorail, CFA and Road studs

Floor Mounted AGVs & Battery Charging


Crude

Transient Analysis
Electrical & Magnetic needs to be done

Magnetic materials
unacceptably brittle (Ferrite) Expensive (Amorphous) and not isotropic

Power Electronics:
Capacitors, Switches are limiting New technology required for larger power sizes (trucks & trains)

Integration of power, data and control Improved performance Lower Cost

Questions ?

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