Wireless Power Transfer System Design

Julius Saitz
ANSYS

1 2011 ANSYS, Inc. April 27, 2015

 WPT System

2 2011 ANSYS, Inc. April 27, 2015

 Wireless Power Transfer (WPT)
Near-Field (Inductive coupling, resonant)
Do not rely on propagating EM waves
Operate at distances less than a wavelength of
transmission signal
Resonance obtained by use of external circuit capacitor
Electric and magnetic fields can be solved separately
Focus of this presentation

Far-Field (resonant)
Operating range to ~10 meters
Self capacitance of coil turns are of importance
Requires full wave solver with coupled electric and
magnetic fields

3 2011 ANSYS, Inc. April 27, 2015

 Design Challenges
Magnetic Analysis
Inductance/Resistance calculations versus frequency
Ensure linear mode operation
Relative Position sensitivity study
Loss evaluation
Effect of temperature on magnetic performance

Circuit Analysis Wireless Power Transfer

Operate in resonant mode, considering magnetic results
Compute efficiency considering relative position
Transient simulation considering frequency dependent effects

Thermal Management
Consider local losses distribution in thermal evaluation
Consider changing of electrical properties with temperature
4 2011 ANSYS, Inc. April 27, 2015
 Outline

Large Gap Transformer Design Using Computational

Electromagnetics

Combination of Circuit and Magnetic Analysis for Resonance

Thermal Management

5 2011 ANSYS, Inc. April 27, 2015

 Large Gap Transformer Design Using
Computational Electromagnetics

6 2011 ANSYS, Inc. April 27, 2015

 Regular Transformer

Low reluctance flux path is available

Mutual Coupling between the coils can be
easily determined using Magnetic Circuit
approach
Leakage flux can be considered to be
negligible
Mutual inductance can be derived using
flux balance
Analytical solution possible within
permissible level of accuracy

7 2011 ANSYS, Inc. April 27, 2015

 Large Gap Transformer

No Specific path for the magnetic flux

Leakage flux is significant enough and can
not be neglected
Analytical methods are proposed for
calculation of Mutual inductance using
Maxwells formula for two coaxial circular
coils

=

Application of these formulas to real life cases is almost impossible

Computation Electromagnetics can help to reduce problem complexity

significantly
8 2011 ANSYS, Inc. April 27, 2015
 Maxwell

9 2011 ANSYS, Inc. April 27, 2015

 Transformers

Lorentz Force
Inductance
Insulation Dielectric Withstand, Creep Stress Curves (V/m) xformer4 ANSOFT

Maximum E-field
4E+006
Curve Info
Allowable Withstand C...
Sorted_E_Tangent
$PermOil='2.2'
3E+006 E_Tangent
$PermOil='2.2'
Cumulative_Stress
$PermOil='1'
Cumulative_Stress
$PermOil='2.2'
2E+006
Cumulative_Stress
$PermOil='6'

V/m
1E+006

0E+000

-1E+006
0.00 0.05 0.10 0.15 0.20 0.25 0.30 0.35 0.40
Distance (m)

Creep Stress
Losses and Temperature
in Ferrite Core

Converters

Load Analysis Foil Losses Tank Wall Losses

Bus Bars

10 2011 ANSYS, Inc. April 27, 2015

 WPT Magnetic simulation Flow Chart
Magnetic Field Solver
+
Circuit / System Simulator

Gap
Sliding
Magnetostatic

Core, Winding

Eddy Current
(time harmonic) Circuit / System
Simulator
Impedance Model
(AC / TR)

Eddy Current Circuit / Drive / Controller design

Waveform, Efficiency, Power
factor, Response
Fields, Losses
11 2011 ANSYS, Inc. April 27, 2015
 Magnetostatic Analysis
Saturation
L2
Magnetic shielding M
Self and Mutual Inductance L1
Coupling Coefficient

12 2012 ANSYS, Inc. April 27, 2015

 Parametric Analysis using Maxwell

13 2011 ANSYS, Inc. April 27, 2015

 Eddy Current (Frequency domain)
Impedance vs frequency
State Space Model for Circuit Analysis
Losses
Eddy current shielding

Core(Power Ferrite)

Shield Plate (Aluminum)

14 2011 ANSYS, Inc. April 27, 2015

 Combination of Circuit and Magnetic
Analysis for Resonance

15 2011 ANSYS, Inc. April 27, 2015

 Inductive Type Coupling Near Field

1) Electromagnetic analysis to determine R, L, M

C C

R R
Magnetic R, L, M
L L
M

2) Resonant circuit realized by a lumped capacitance parameter in

the circuit simulator

16 2012 ANSYS, Inc. April 27, 2015

 System Approach with Simplorer

Reduced Order Model (ROM)

Secondary Coil

Primary Coil
17 2011 ANSYS, Inc. April 27, 2015
 Frequency Domain Analysis: System Level

18 2011 ANSYS, Inc. April 27, 2015

 Parametric Analysis: Frequency Domain

Bode Plot: Load Voltage vs Gap

Gap
Sliding

Bode Plot: Load Voltage vs Slide

Geometric parameters are
Available in the circuit
environment

19 2011 ANSYS, Inc. April 27, 2015

 Transient Analysis

20 2011 ANSYS, Inc. April 27, 2015

 Efficiency Map

Output/Input Power
Tuned capacitance for each conditions
Max.96%
P VI cos
Pout 90%
100[%]
Pin Efficiency[%]
Efficiency[%] 50%
Gap [mm]

20%

Gap [mm] Sliding [mm]

Sliding [mm]
21 2011 ANSYS, Inc. April 27, 2015
 Optimize the Design: Various Shape Types

Disk Coil type Solenoid Coil type

22 2011 ANSYS, Inc. April 27, 2015

 Efficiency as a function of sliding direction and
distance
Gap between coils kept constant

23 2011 ANSYS, Inc.

 Efficiency as a function of gap between coils

Zero sliding
Gap

24 2011 ANSYS, Inc.

 System Simulation WPT

T HREE_PHASE1 IGBT
IGBT 1 1 D1D1 IGBT
IGBT 3 3 D3D3
T HREE_PHASE1
D5D5 D7D7 D9D9

3PHAS
3PHAS WM1
WM1 WM2
WM2
CsCs R1R1 R2R2
A *Asin
* sin
(2 *(2pi* *pif * tf +
* tPHI
+ PHI + phi_u)
+ phi_u) ++ ++
Current_1st_1:src
Current_1st_1:src D11
D11 D13
D13
WW Current_2nd_1:src
Current_2nd_1:src WW
PHIPHI = 0
= 0 Rload
Rload
~~ 1.93uF
1.93uF
(1/87-0.004)
(1/87-0.004) ohmohm
Current_2nd_1:snk
Current_2nd_1:snk (1/348-0.001)
(1/348-0.001) ohm
ohm
Current_1st_1:snk
Current_1st_1:snk 10ohm
10ohm

PHIPHI = -120
= -120 Current_1st_2:src
Current_1st_2:src CpCp C2C2
~~ C1C1
Current_2nd_2:src
Current_2nd_2:src
Current_2nd_2:snk
Current_2nd_2:snk 5.24uF
5.24uF 1e-006farad
1e-006farad
Current_1st_2:snk
Current_1st_2:snk
1000uF
1000uF
PHIPHI = -240
= -240
~~
IGBT
IGBT 2 2 D2D2 IGBT
IGBT 4 4 D4D4 D12
D12 D14
D14
- - ++
D6D6 D8D8 D10
D10 Battery
Battery

LBAT
LBAT T _A1
T _A1

0 0
Wireless Power Transformer Battery
00

AC200V Rectify0 0 Inverter 40.00

40.00 Curve
Curve Info
Info rms
rms
WM1.I
WM1.I 9.4139
T RANS1 TR
TR 9.4139
T RANS1
T RANS2
T RANS2 WM2.I 10.5939
WM2.I 10.5939
STST
ATAT E_11_1
E_11_1 STST
ATAT E_11_2
E_11_2 TR
TR
FML_INIT
FML_INIT 1 1 20.00
20.00
ICA:
ICA:

Modulation_Index:=0
Modulation_Index:=0
Carrier_Freq:=10k
Carrier_Freq:=10k SET
Frequency:=10k SET : T :SV4:=1
T SV4:=1 SET
SET : T:SV4:=0
T SV4:=0
Frequency:=10k

Y1 [A]
SET
: T :SV3:=0
T SV3:=0 SINE1.VAL
SINE1.VAL
< T<RIANG1.VAL
T RIANG1.VALSET
SET
: T:SV3:=0
T SV3:=0 DTDT
1 1

Y1 [A]
SET
SET
SET : T :SV2:=0
T SV2:=0 SET
SET : T:SV2:=0
T SV2:=0 0.00
0.00
Dead_T
Dead_T ime:=2u
ime:=2u SET
SET : T :SV1:=1
T SV1:=1 SET
SET : T:SV1:=0
T SV1:=0
DC_Source:=200
DC_Source:=200 DEL:
DEL: DTDT 1##Dead_T
1##Dead_T imeime
SINE1
SINE1
T RANS3
T RANS3
T RANS4
T RANS4 -20.00
-20.00
AMPL=Modulation_Index
AMPL=Modulation_Index STST
ATAT E_11_4
E_11_4 STST
ATAT E_11_3
E_11_3
FREQ=Frequency
FREQ=Frequency

T RIANG1
T RIANG1
SET
SET : T :SV4:=0
T SV4:=0
Controller SET
SET : T:SV4:=0
T SV4:=0
-40.00
-40.00
0.00
0.00 0.25
0.25 0.50
0.50 0.75
0.75 1.00
1.00
Time [ms]
1.25
1.25 1.50
1.50 1.75
1.75 2.00
2.00
AMPL=1 DTDT
4 4 SET
SET : T :SV3:=0
T SV3:=0SINE1.VAL
SINE1.VAL
> T>RIANG1.VAL
T RIANG1.VAL SET
SET : T:SV3:=1
T SV3:=1 Time [ms]
AMPL=1 SET
FREQ=Carrier_Freq SET : T :SV2:=0
T SV2:=0 SET
SET : T:SV2:=1
T SV2:=1
FREQ=Carrier_Freq SET
SET : T :SV1:=0
T SV1:=0 SET
SET : T:SV1:=0
T SV1:=0
DEL:
DEL: DTDT 4##Dead_T
4##Dead_T imeime
300.00
300.00 Curve Info rms
Curve Info rms
WM1.V 154.9045
TR WM1.V 154.9045
TR
40.00
40.00 Curve Info 200.00
Y Axis 200.00
rms
Curve Info Y Axis rms WM2.V 120.2425
156.0455 WM1.I
WM1.I TR WM2.V 120.2425
TR
156.0455
TRTR Y1Y1 9.3501
9.3501
131.1979
131.1979 WM2.I
WM2.I
20.00
20.00 TRTR Y1Y1 10.5176
100.00
10.5176
100.00 100.00
100.00
WM1.V
WM1.V
TRTR Y2Y2 153.6594
153.6594
27.9814
27.9814
Y1 [V]

WM2.V
Y1 [A]

Y2 [V]

Y1 [V]

WM2.V
Y1 [A]

Y2 [V]

0.00 -0.0090
-1.2036 1.3406
1.3406 TRTR
-0.5141 Y2Y2 119.4615
119.4615
0.00
0.00 -0.0090
-1.2036 -0.5141 0.00
-6.0797
-6.0797
-100.00
-100.00
-20.00
-20.00 -100.00
-100.00

-40.00
-40.00 -200.00
1.90
1.90 1.92
1.92 1.94
1.94 1.96
1.96 1.98
1.98 2.00-200.00
2.00
Time
Time [ms]
[ms] -300.00
-300.00
MX1:
MX1: 1.9753 0.0030
1.9753 0.00 0.25 0.50 0.75 1.00 1.25 1.50 1.75 2.00
MX2: 0.0030
1.9783 0.00 0.25 0.50 0.75 1.00
Time [ms] 1.25 1.50 1.75 2.00
MX2: 1.9783 Time [ms]

25 2011 ANSYS, Inc. April 27, 2015

 Thermal Management

26 2011 ANSYS, Inc. April 27, 2015

 Temperature in ANSYS Mechanical or CFD

Ohmic Loss

Temperature

Core Loss

27 2011 ANSYS, Inc. April 27, 2015

 Summary
ANSYS offers a comprehensive modeling solution for Wireless Power Transfer
systems:
Magnetostatic THREE_PHASE1 IGBT1 D1 IGBT3 D3
D5 D7 D9

3PHAS WM1 WM2

Frequency domain
Cs R1 R2
A * sin (2 * pi * f * t + PHI + phi_u) + +
Current_1:src D11 D13
W Current_2:src W
PHI = 0
~ 1.72uF
7.2mOhm 3.6mOhm Rload

13ohm
Current_1:snk
PHI = -120 Current_2:snk
~ C1
Cp C2

4.96uF 1uF
1000uF
PHI = -240
~ IGBT2 D2 IGBT4 D4 D12 D14
- +
D6 D8 D10 Battery

Circuit and system level 0

0
700.00
Curve Info

TR
WM1.V
0

rms
LBATT_A1

281.0066

PWR_Probe1 WM2.V
TR 321.9453
TRANS1

Thermal
TRANS2
PWR
STATE_11_1 STATE_11_2
Probe
FML_INIT1 200.00
ICA:

Y1 [V]
Modulation_Index:=0 PWR_Probe2
Carrier_Freq:=20k SET: TSV4:=1 SET: TSV4:=0
Frequency:=20k PWR
SET: TSV3:=0 SINE1.VAL < TRIANG1.VAL SET: TSV3:=0 DT1
SET: TSV2:=0 SET: TSV2:=0 Probe -300.00
Dead_Time:=2u
SET: TSV1:=1 SET: TSV1:=0
DC_Source:=400 DEL: DT1##Dead_Time
SINE1
TRANS3
TRANS4
AMPL=Modulation_Index STATE_11_4 STATE_11_3
FREQ=Frequency
-800.00
2.00 2.20 2.40 2.60 2.80 3.00
Time [ms]
TRIANG1

SET: TSV4:=0 SET: TSV4:=0

DT4 SET: TSV3:=0 SINE1.VAL > TRIANG1.VAL SET: TSV3:=1
AMPL=1
SET: TSV2:=0 SET: TSV2:=1
FREQ=Carrier_Freq
SET: TSV1:=0 SET: TSV1:=0
DEL: DT4##Dead_Time
150.00 Curve Info rms
WM1.I
TR 41.6165

250.00 Curve Info Y Axis873.02

rms 100.00 WM2.I
TR 34.8648
WM1.I
TR Y1 38.9542

WM2.I
500.00 50.00
125.00 TR Y1 34.1140

WM1.V

Y1 [A]
TR Y2 276.0822

Y1 [A]

Y2 [V]
0.00 0.00
0.00 -0.0037 WM2.V
TR Y2 316.6292
-40.2840 -53.6971
-64.8250 -315.0105 -319.5653
-408.7847 -377.1247 -50.00
-125.00 -500.00

-100.00
-250.00 -1000.00
2.900 2.925 2.950 2.975 3.000
Time [ms]
-150.00
MX1: 2.9200 0.0610 2.00 2.20 2.40 2.60 2.80 3.00
MX2: 2.9811 Time [ms]

System Level Modeling

Electromagnetic-Circuit

Wireless Power Transfer

Electromagnetics
28 2012 ANSYS, Inc. April 27, 2015