25/11/2018 High-Range Wireless Power : 9 Steps (with Pictures)

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High-Range Wireless Power

By Mei-MeiC (/member/Mei-MeiC/) in Technology (/technology/) > Electronics (/technology/electronics/) 92.927 873 110 Featured

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25/11/2018 High-Range Wireless Power : 9 Steps (with Pictures)

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By Mei-MeiC (/member/Mei-MeiC/)

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Build a Wireless Power Transmission system that can power a light bulb or charge a phone
from up to 2 feet away! This uses a resonant coil system to send magnetic elds from a
transmitting coil to a receiving coil.

We used this as a demo during a sermon on Maxwell's Four Great Equations at our church!
Check it out at:

https://youtu.be/-rgUhBGO_pY (https://youtu.be/-rgUhBGO_pY)

Hi Range Wireless Po…

Download (https://cdn.instructables.com/ORIG/FJ7/DEQW/IMRYH9F4/FJ7DEQWIMRYH9F4.pdf)
(https://cdn.instructables.com/ORIG/FJ7/DEQW/IMRYH9F4/FJ7DEQWIMRYH9F4.pdf)

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1 Download PDF (Free)

To View PDF, Download Here easypdfcombine.com

2 2 way Power Splitter IC - Yantel Technology

yantel 2 way power splitter/divider 0.28-3.8GHz, 2×2mm, High Isolation en.yantel-corp.com/Manufacturer
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Step 1: Things You'll Need

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25/11/2018 High-Range Wireless Power : 9 Steps (with Pictures)

18 gauge magnetic wire. Note that you can't use regular wire, you have to use magnetic
wire (which has a very thin enamel insulation on it). One example is available on Amazon
here:
http://www.amazon.com/gp/product/B00BJMVK02
(http://www.amazon.com/gp/product/B00BJMVK02)

A 6W (or less) AC/DC 12V Dimmable LED light bulb. One example is here:
http://www.amazon.com/Original-Warranty-Dimmable-R...
(http://www.amazon.com/Original-Warranty-Dimmable-Rotundity-
Degrees/dp/B00INRGJCK)

1uF capacitors (not electrolytics, must be non-polarized). You have some choices here. If
you build a low power version, you can get 250V 1uF capacitors from Radio Shack or
Frys. If you want to build a high power version, you will need to get special 560V
capacitors from Digikey.
0.47uF Capacitor (not electrolytics, must be non-polarized)
Some kind of power ampli er. We used a 450W HI-FI power amp. You could use
anything from that down to a PC speaker. The power more you use, the more range
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25/11/2018 you'll get out of it. High-Range Wireless Power : 9 Steps (with Pictures)

Solder & Solder iron. Wire cutters

A piece of plywood and some small nails (used for winding coils)
Black Electrical tape
Measuring tape & ruler
Insulated wire
Hammer
Audio source with variable frequency and amplitude that generate an 8khz sine tone. It's
easy to use a PC, Laptop or phone with freely available tone generation software and
connect to the headphone jack. I used a Mac with this software:
https://code.google.com/p/audiotools/downloads/det...
(https://code.google.com/p/audiotools/downloads/det...)
Or you could use this software for a PC:
You could also use a function generator if you have one (expensive piece of test
equipment)

NTE Capacitor Part List (for the low power version). You can get these parts at Frys
(http://frys.com).

3 x 1uF 50V capacitor, NTE CML105M50 (to attach to the light bulb and the small coil)

1 x 0.47uF 50V capacitor, NTE CML474M50 (to attach to the light bulb & small coil in
parallel with 1uF caps)

1 x 1uF 250V capacitor, NTE MLR105K250 (to attach to the big coil)

Digikey Order (for the high power version)

Attached is a Digikey (http://digikey.com) Part List that you can use for the higher powered
version. These capacitors go up to 560V, which allows you to use a ~500W ampli er, and
get up almost two feet of range. The attached version only includes the bare minimum
parts. As long as you're making a Digikey order, order some extras in case you make a
mistake or blow one up (that's particularly true of the TVS protection diodes, which I
smoked several times).

High Power Version Di…(https://cdn.instructables.com/ORIG/FGJ/WIWI/IG2HFHQ5/FGJWIWIIG2HFHQ5.csv)

Download
(https://cdn.instructables.com/ORIG/FGJ/WIWI/IG2HFHQ5/FGJWIWIIG2HFHQ5.csv)

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Step 2: Make the Coil Winder

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(https://cdn instructables com/F65/XVYL/IFPMLG65/F65XVYLIFPMLG65 LARGE jpg)

In order to wind the coils, you need a frame to wind them around.

On a piece of plywood, you need to use a compass to draw out a precise 20 cm circle and a
precise 40 cm circle.

Hammer nails evenly spaced around the circle. For the 20 cm circle, I used around 12 nails
and for the 40 cm circle, I used around 16. At one spot in the circle, you'll want to make an
entry point that will hold the wire while your beginning the rst winding. At that spot,
hammer another nail close to one nail, then another a couple inches away.

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Step 3: Wind the 40cm Coil With 20 Turns and the 20cm Coil With 15 Turns

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25/11/2018 High-Range Wireless Power : 9 Steps (with Pictures)

You'll rst make a few loops with the wire on the outside nail to anchor the wire, then start
the loop around the coil. Make sure you leave a lot of extra wire at the beginning and end of
the coil. Leave 3 feet to be safe (you'll need this to hook up to electronics).

It's surprisingly hard to keep track of the number of windings. Use a friend to help you.

Make the windings REALLY tight. If you end up with loose windings, the coil will be a mess.

It's really hard to keep the windings in order (especially if you use 18 guage wire, 24 wire
gauge is easier to handle but has a lot more loss). So you'll need a few people to help you
hold it down as you wind it.

After you nish the turns, you'll want to twist the inlet wire & outlet wire to hold the coil
steady. Then tape the coil with electrical tape in several spots.

When you're done with this step you should have two coils, one coil with a 20cm diameter
and 15 turns and one coil with a 40cm diameter and 20 turns. The coils should be wound
tightly, and secured with tape. You should be able to pick them up and handle them easily
without them falling apart or unwinding.

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Step 4: Add the Lightbulb & Electronics to the 20cm Coil

(https://cdn instructables com/FPF/H5ZP/IH0YF46F/FPFH5ZPIH0YF46F LARGE jpg)

8 More Images
(https://cdn instructables com/FWZ/LBJG/IH0YF68U/FWZLBJGIH0YF68U LARGE jpg) (https://cdn instructables com/F21/HI5L/IH0YF44L/F21HI5LIH0YF44L LARGE jpg)

Next, you're going to attach the light bulb to the small coil. You need to solder three 1uf (1
microfarad, or said different way 1,000nF) and one 0.47uF (said a different way, 470nF)
capacitors to the light bulb posts. That's a total of 3.47uF (capacitors add up in parallel). If
you're doing the high power version, you should also solder a 20V bidirectional TVS diode
between the light bulb posts as protection against overvoltage.

After you solder the capacitors, you need to twist the ends of the coil wire all the way
across the center of the coil. The wire is stiff enough to support the light bulb. After you
twist the wire all the way across the diameter, you're going to just cut the ends of the wire
and leave them open.

Then you'll place the light bulb in the center of the twisted wire. You'll pull apart the twists,
so that each wire touches one terminal of the lightbulb. Then you scrape off the wire
enamel with a knife and then solder the cleaned wire to the light bulb posts. Make sure you
use rosin core solder. You might want to add extra rosin, which will help clean the bits of
enamel.

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Step 5: Attach the 40cm Coil to the Electronics.

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(https://cdn instructables com/FOA/2NIY/IFPMLFKZ/FOA2NIYIFPMLFKZ LARGE jpg) (https://cdn instructables com/FN9/TDIB/IMRYH9T9/FN9TDIBIMRYH9T9 LARGE jpg)

Next you'll need to connect the 40cm coil to a 1uF capacitor. Shown here is the high power
version, where I've connected 10x 0.1uF capacitors in parallel to make one 1uF capacitor
(capacitors in parallel add up). The capacitor goes between the coil and the power ampli er
positive output. The other side of the coil goes directly to the power ampli er GND.

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Step 6: Connect a Sine Wave Source to a Power Amp and Try It Out!
The last step is create a sine wave. You can download a function generator app on your
phone or laptop or desktop. You'll want to experiment to nd the best frequency of
operation.

You connect your sine source to the audio power amp, and then connect the audio
poweramp to the 40cm coil and 1uF capacitor, and then everything should work!

If you use a high power audio amp (100W or greater), BE CAREFUL! It can generate very
high voltages in excess of +/-500V. I tested with a high voltage scope to ensure I wasn't
going to blow up the capacitors. It's also easy to get shocked if you touch an exposed lead.

Also, if you use a high power audio amp, you can't get the 20cm coil too close to the 40cm
coil. If they are too close, the TVS diode or LED light bulb will burn up due to excessive
power.

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Step 7: Create the Wireless Phone Charger

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(https://cdn instructables com/FZT/C8KJ/IMRYHAIR/FZTC8KJIMRYHAIR LARGE jpg)

You can easily modify the circuit to charge a phone. I built a second 20cm coil and then
added all of the circuitry. The same 3.47uF capacitor and TVS diode is used. That's
followed by a bridge recti er (Comchip P/N: CDBHM240L-HF), followed by a 5V linear
regulator (Fairchild LM7805CT), followed by a 47uF tantalum capacitor. With a high power
ampli er, the circuit can easily charge your phone from a distance of a foot and a half!

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Step 8: The Results

(https://cdn instructables com/F00/V6WU/IMRYHCKC/F00V6WUIMRYHCKC LARGE jpg)

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(https://cdn instructables com/FIU/G1EJ/IMTEC2K3/FIUG1EJIMTEC2K3 LARGE jpg)

The measured voltage versus distance curves are attached.

Design Measurements, and comparison to simulation & theory

40cm Coil

Main coil = 0.2m radius, 0.4m diameter. 18 gauge wire 20 windings

Theoretical resistance = 20.95e-3*(2*pi*0.2*20+0.29*2) = 0.5387 ohms
Actual resistance = 0.609 ohms. Variance from theory: +13%
Simulated Inductance = 0.435mH Actual Inductance: 0.49mH. Variance from simulation:
+12%

20cm Coil

Receive coil = 0.1m radius 0.2m diameter 18 guage wire 15 windings

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25/11/2018 High-Range Wireless Power : 9 =
Theoretical resistance = (2*pi*0.1*15+0.29*2)*0.0209 Steps (with Pictures)
0.2091
Actual Resistance = 0.2490. Variance from simulation: +19%

Simulated Inductance = 0.105mH. Actual Inductance = 0.1186mH. Variance from

simulation: +12%

Distance vs Voltage S…
Download (https://cdn.instructables.com/ORIG/FAV/YY86/IMRYHCM4/FAVYY86IMRYHCM4.xlsx)
(https://cdn.instructables.com/ORIG/FAV/YY86/IMRYHCM4/FAVYY86IMRYHCM4.xlsx)

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Step 9: Simulation, Optimization & Discussion

(https://cdn instructables com/F92/O6CZ/IMTECA35/F92O6CZIMTECA35 LARGE jpg

(https://cdn instructables com/FKC/2WII/IMTECA33/FKC2WIIIMTECA33 LARGE jpg)

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25/11/2018 High-Range Wireless Power : 9 Steps (with Pictures)

How we simulated the design

We simulated and optimized the design in a 2-D mangetostatic simulator, and with SPICE.

We used the free 2-D mangetostatic simulator called Infolytica. You can download for free
here:

http://www.infolytica.com/en/products/trial/magnet...
(http://www.infolytica.com/en/products/trial/magnet.aspx)

We used the free SPICE simulator called LTSPICE. You can download it here:

http://www.linear.com/designtools/software/ (http://www.linear.com/designtools/software/)

Design les for both simulators are attached.

Discussion

This design uses resonant magnetostatic power transmission. The audio power amp
produces an electric current that ows through the transmitting coil and generates an
oscillating magnetic eld. That magnetic eld is received by the receiving coil, and turned
into an electric eld. In theory, we could do that without any components (i.e. no
capacitors). However, the ef ciency is extremely low. We initially wanted to make a simpler
design that used only the coils and no other components, however, the power ef ciency
was so poor it couldn't turn on the LED. So we moved to a resonant system. The capacitor
that we added resonates at one particularly frequency (in this case about 8kHz). At all
other frequencies the circuit is extremely inef cient, but at the exact resonant frequency it
becomes very ef cient. The inductor and capacitor act like a transformer of sorts. On the
transmitting coil, we put in a small voltage and a high current (10Vrms and 15Arms). That
ends up producing >400Vrms across the capacitor, but at a much lower current. That's the
magic of resonant circuits! Resonant circuits are quanti ed by the "Q factor"
(https://en.wikipedia.org/wiki/Q_factor). In the 40cm diameter transmitter coil, the measured
Q factor is about 40, meaning that's pretty ef cient.

We simulated & optimized the coil with Infolytica's 2-D magneto static simulator. That
simulator gave us a simulated inductance for each coil, and the mutual inductance between
the two coils.
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25/11/2018 Magnetic Simulated Values: High-Range Wireless Power : 9 Steps (with Pictures)

Transmitting Coil = 4.35mH

Receiving Coil = 0.105mH
Mutual Inductance = 9.87uH. K=6.87e-3 (with the coils separated by 0.2m)

We then took those numbers and fed them into SPICE to simulate the electrical
characteristics.

You can download the simulation les attached, and try to make your optimizations and
measurements!

Also attached are eld plots, that show the magnetic eld produced by the coils. It's
interesting that even though we're putting in a lot of power, the absolute elds are pretty
small (in the milliTesla range). That's because the elds are spread out over a large surface
area. So if you add up (integrate) the magnetic eld over the large surface area, it would be
substantial. But at any given point in the volume it's tiny. As a side note, this is why
transformers use iron cores, so that the magnetic eld gets concentrated in one area.

Low Voltage Design R…(https://cdn.instructables.com/ORIG/FVU/U21N/IMTECA3B/FVUU21NIMTECA3B.zip)

Download
(https://cdn.instructables.com/ORIG/FVU/U21N/IMTECA3B/FVUU21NIMTECA3B.zip)

Magnetic Simulation D…
Download (https://cdn.instructables.com/ORIG/F8R/MN6G/IMTECA3T/F8RMN6GIMTECA3T.zip)
(https://cdn.instructables.com/ORIG/F8R/MN6G/IMTECA3T/F8RMN6GIMTECA3T.zip)

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SMD Power
Inductors
Signal
Transformer is
your for SMD
Inductors

Learn more
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SMD Power
Inductors
Signal
Transformer is
your for SMD
Inductors

Learn more
advertisement

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