INDUCTIVE POWER TRANSFER CHARGING STATION FOR STATIC AND DYNAMIC CHARGE OF ELECTRICAL VEHICLES

Presented by: Anton Tonchev, Technical University - Gabrovo

UNITECH 2014

Prof.Raycho Ilarionov, assoc prof. Nikolay

Madzharov

Innovative fast charging solution for electric vehicles

The main task of the project is development of High Power Contactless Charging System for Electric Vehicles.

The system must have efficiency greater than 85 percent and to provide conditions for accelerated charging of the vehicle.

Innovative fast charging solution for electric vehicles

PARTNERS IN THE PROJECT

Starting date: 01/10/2012 End date:30/09/2015

FastInCharge is lead by a consortium of 9 partners from 6 countries:

France, Bulgaria, Italy, Spain, Greece and Slovakia.

The list includes :

1.Companies, specialized in charging infrastructure for EV

2.Automotive engineering companies

3.Research organizations

4.Specialists of power electronics and energy management systems

5.Project management organizations

Innovative fast charging solution for electric vehicles

ALL PARTNERS IN THE PROJECT

Starting date: 01/10/2012 End date:30/09/2015

DOUAISIENNE DE BASSE TENSION SAS ("DBT") France www.dbt.fr

TECHNICAL UNIVERSITY – GABROVO ("TUG") Bulgaria www.tugab.bg

AUTOMOBILOVY KLASTER ("ACWS") Slovakia www.autoklaster.sk

BATZ SOCIEDAD COOPERATIVA("BATZ") Spain www.batz.com

COMMUNE DE DOUAI ("DOUAI") France www.ville-douai.fr

EUROQUALITY ("EQY") France www.euroquality.fr

INSTITUTE OF COMMUNICATION AND COMPUTER SYSTEMS("ICCS") Greece www.iccs.gr

FUNDACION TECNALIA RESEARCH & INNOVATION("TECNALIA") Spain www.tecnalia.com

CENTRO RICERCHE FIAT SCPA("CRF") Italy www.crf.it

The main R&D partners of the project

DBT - DOUAISIENNE DE BASSE TENSION SAS ("DBT") France ,

www.dbt.fr

Lead partner in the project.Cable charging stations

manufacturer, partner with Renault – Nissan Alliance

TECHNICAL UNIVERSITY – GABROVO ("TUG"),

Bulgaria www.tugab.bg

Main R&D leader in the project. Part of the tasks: R&D of Inductive Power Transfer

systems – inverter, IPT coils, compensation & etc.

Research center of FIAT Group ("CRF"), Italy

www.crf.it

Development of communication system

between EV and Charging Station.

Provides the EV – IVECO Daily Hybrid and Li-ion Battery Pack

FUNDACION TECNALIA RESEARCH & INNOVATION

("TECNALIA") Spain www.tecnalia.com

Development of IPT secondary coil positioning system,

installed on the EV

The main R&D partners of the project

Project tasks and goals• Development of two charging stations (static and on-route) to be

integrated in Douai , France – one station for static charging, one station with four coils for test of dynamic charging mode (TU-Gabrovo team)

• Development of one secondary receiving (Rx) coil to be integrated on the vehicle – IVECO Daily

• System have to be able to control the charging current from the charging station inverter - no secondary side active converter!

• Optimization of the energy management system.

• Demonstration of the efficiency and viability of the solution in real-life conditions (TU-Gabrovo team)

• Study on the exploitation of the solution and the integration in other vehicles and situations.

• Evaluation of the impact.

Work Packages (WP) structure

WP1: Specifications

WP3: Development of integration solutions:

power supply from the grid, energy management,

data security

WP2: Development of static and on-route fast

inductive charginginfrastructure: vehicle and

stations

WP4: Integration, prototyping and testing

WP5: Demonstration and impact analysis

WP

7: M

anage

me

nt

WP

6:

Dis

sem

inat

ion

and

exp

loit

atio

n

2014 ÷ 2015

2015

20

14

÷2

01

52

01

4 ÷

20

15

Simplified Topology of the IPT Charging Station

LF

DC

10-30kHz

Converter Control

HF

DC

3x380V / 50Hz

HFDC

DC LOAD

Inductive Power Transfer (IPT) Coils

Key feature of the system:

Output charging current

regulation via primary side

inverter!

FEEDBACK & LOGIC FEEDBACK & LOGICWi-Fi

TX RX

IPT coils - construction

Main structural

components of IPT

equivalent transformer :

1.Aluminum cover

2.HF Windings – flat spiral

coils, made from LITZ wire;

3.Ferrite bars

IPT coils – electromagnetic field Aluminum cover main function – Electromagnetic shield

Ferrite bars – “magnetic shaping” , Coupling and Quality factors improvement

Combination of both – decreasing the levels of electromagnetic dissipation: maximum

occupational levels of 27µT @ 3-150kHz, according to ICNIRP Guidelines

IPT coils – important parameters

The equivalent

transformer with large

air gap is the main

“efficiency determining”

module in the

contactless charging

station!

Representation of parameters, used for IPT coils design and calculation process

IPT coils – coupling factor

Coupling factor values for different levels of misalignment between Tx and Rx coil

IPT coils – quality factor and losses

Efficient IPT system is based on:

•Small air gap and good coupling factor;

•Appropriate Litz wire cross section and strands dimensions;

•Converter frequency is equal to frequency with highest quality factor of IPT coils;

IPT coils – design results

Secondary (Rx) coil 2000Vrms / 10kHZ

Secondary (Rx) coil 1200Vrms / 20kHZ

Turns: 13Wire length: 26mWire mass: 7.4kgSpacing: NoInductance: 250µH

Number of ferrite plates: 144Mass of ferrite plates : 19kgOverall mass: 39kg

Coupling factor: 0.52Coil losses: 3.3%

Turns: 7Wire length: 14mWire mass: 4kgSpacing: 8mmInductance: 60µH

Number of ferrite plates: 58Mass of ferrite plates : 7.7kgOverall mass: 24kg

Coupling factor: 0.45Coil losses: 2%

Charging station side – Matching and compensation

The only possible solution for achieving good efficiency is the use ofresonant magnetic coupling between coils. There are many possiblecompensation topologies – serial, parallel, mixed. The choice ofcompensation depends from output power and application of the system.

T-shape with serial compensation (S-S) to П-shape with parallel (P-P) compensation

Charging station side – Matching and compensation

Impedance of IPT system for operation at resonant frequency ω = ω0

The design process based on equal inductances LTX = LRX and Serialcompensation in both sides of IPT is much simpler for analysis and practicalimplementation. The impedance is:

Charging station side – Matching and compensation

2 Primary Matching transformers for every TX Coil, connected in series with transformation ratio 2:1

70A primary current / 210A secondary for each one

2 HF Series connected capacitor banks (2.4uF / 2000V) for compensation of IPT Charging Coil

Compensation module (used for two Tx coils)

Charging station side – IGBT inverter

Advanced Full Bridge Topology

One “common” IGBT module in continuous operation mode

Four IGBT modules for the four Charging Coils (Transmitters)

Single DC busbar system

Common HF potential point (from the “common” IGBT module)

Charging station side – IGBT inverter

Modular design – simple integration in the charging station housing

PCB based inverter busbar

Shielded construction for high electromagnetic noise immunity of control boards

FPGA control system

Air cooled

Five gate drivers for each module

High pulse power capability –up to 45kW @ 1min

“5 in 1” inverter module, based on PCB Busbar system

Modular design

Standard housing, manufactured by DBT, France

Complex air cooling system

High IP protection IP55 with back covers installed

1 – Input filter, protection and main contactor

2 – IGBT Inverter

3 – Matching and Compensation modules

Charging station side – modules distribution

Charging station power modules distribution

Electric vehicle side – compensation and HF rectifier

COMPENSATION AND HF RECTIFICATION MODULE DESIGN GOALS :

Small volume and mass – 540mm x 400mm x 100mm, 12kgHigh efficiency - up to 98%High level of protection against dust and moistureOutput differential current and voltage measurementSelf diagnostic and cooling control

CAN BUS ANALOG AND DIGITAL SIGNALS HF POWER SIGNALS

Wi - Fi

PLC PLC

Wi-Fi toCANBUS

Wi-Fi toCANBUS

Battery pack

IGBT Inverter Matching and Compensation

Secondary compensation and HF rectifier

Test results

Parameter Value Note

Nominal Input Power 35kVA According to specifications

Peak Input Power 45kVA @ 1min Available for "On route"

Efficiency, [%] up to 92% 35kW @ 90mm

Nominal Input Voltage 1200V RMS @ 13kHz Continuous mode

Nominal Input Current 300A RMS @ 13kHz Continuous mode

Transformation ratio 7:7 Primary to secondary

Primary (Tx) coil dimensions 700mm x 800mm x 90mm

Secondary (Rx) coil dimensions 700mm x 800mm x 60mm

Switching Frequency, [kHz] 25kHz ÷ 13kHzDepends from the compensation,

misalignment and type of coils

Primary winding mass, [kg] 28kg For the transmitter

Secondary winding mass, [kg] 24 kg For the receiver

Gap, mm Up to 90mm For appropriate efficiency

Horizontal misalignment, mm ΔX=ΔZ= ± 150mm For appropriate efficiency

Test results

The end of the project

On-route charging station project.

By the end of September 2015 the “On Route” Dynamic charging system will be tested in real urban environment in the

city of Douai, France

Thank you for your attention