A Novel Transformer for Contactless Energy Transmission Systems Wei Zhang

Nanjing University of Aero. & Astro. No.29 Yudao Street Nanjing, 210016, China coreper@163.com

Qianhong Chen
Member, IEEE Nanjing University of Aero. & Astro. No.29 Yudao Street Nanjing, 210016, China chenqh@nuaa.edu.cn

S.C.Wong
Senior Member, IEEE Hong Kong Polytechnic University enscwong@polyu.edu.hk

Chi K.Tse
Fellow, IEEE Hong Kong Polytechnic University encktse@polyu.edu.hk

Xinbo Ruan
Senior Member, IEEE Nanjing University of Aero. & Astro. No.29 Yudao Street Nanjing, 210016, China ruanxb@nuaa.edu.cn

Abstract -- Coupling coefficient k of a transformer is a key parameter affecting the efficiency of a contactless energy transmission systems (CETS). Aiming to obtain higher k, smaller size and lighter weight for the contactless transformer, techniques for the improvement of core structure and coil arrangement are proposed in this paper. A new magnetic reluctance circuit is also proposed for the transformer. Based on magnetic flux coupling, magnetic reluctances are found for the calculation of k . A novel contactless transformer is fabricated for a 60W CETS. The k calculated is verified with experimental measurement to be very accurate. A contactless transformer with k of 0.6 and weight of 60g is achieved. Compared with our previous transformer having k of 0.53 and weight of 122g, the new transformer offers about 2.5% improvement in the maximum efficiency. Index Terms-- contactless transformer, coupling coefficient, magnetic reluctance circuit, optimization

Fig. 1.

Sketch of CETS

I. INTRODUCTION Contactless power transmission system (CETS) delivers electrical energy to load with the help of contactless transformer that has no mechanical contact. Due to the distinct advantages of reliability, safety and flexibility, CETS finds increasing applications to supply electricity to mobile facilities such as cell phone, electric vehicle and totallyimplanted devices, especially in the moist or hazardous surroundings [1-5]. The sketch of a CETS is shown in Fig.1. It consists of DC-toAC inverter, contactless transformer, rectification circuit, contactless feedback and receiving circuit, and control circuit. Contactless feedback and receiving technology is relatively mature, including the IR feedback in SAE J-1773[6] and magnetic field feedback in [7]. As the key component of a CETS, the contactless transformer usually has relatively large leakage inductances and significantly reduced magnetizing inductance due to the separation of primary and secondary with a large air gap, resulting in low gain and high loss for the CETS. Therefore, converter topologies which incorporate the leakage inductances into the circuit operation such as resonant and soft-switched topologies are excellent choices in CETS applications [8-10].

*Supported by National Natural Science Foundation of China and Award Number: 50507009; also supported by Hong Kong Research Grants Council
under project PolyU 5306/06E

Although a resonant topology can alleviate the problems associated with the large air gap, low coupling coefficient of the contactless transformer is still the bottleneck limiting the efficiency of a CETS [11-13]. For instance, in the 60W CETS [14], having a contactless transformer with coupling coefficient of 0.532 at an air gap of 10mmthe converter of the system can achieve a maximum efficiency of 88% at full load. Analogously, the coupling coefficient of the transformer adopt by [7] is 0.390 at the same condition, while the maximum efficiency of the converter is only 78% at full load. There are investigations to improve the coupling coefficient of the transformers at the expense of large volume and heavy weight. A contactless transformer with the external diameter of 520mm and the weight of 17.2kg was proposed in [15], whose application value was weakened by the large size and heavy weight. Hence, an improved one was developed [16], by splitting up the entire cylindrical core to several fan shapes, attaining a k of 0.5 at an air gap of 50mm. Similar problems remains in the CETS for artificial hearts. The core of POT66/56 with the weight of 550g is adopted in [7], and planar core of E64/10/50 with the weight of 122g is used in [14]. Improving the transformers coupling coefficient and reducing its size and weight simultaneously becomes a challenge for the CETS. In this paper, a novel structure of transformer is presented along with its magnetic reluctance circuit. The magnetic flux of the transformer is classified into three parts according to its coupling characteristics. And thus the expressions of the reluctance and the coupling coefficient are derived for the improved contactless transformer. Moreover, a novel optimized planar U core with extension leg is presented to

978-1-4244-2893-9/09/$25.00 2009 IEEE

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Fig. 2.(a) Transformer structure

Fig.2. (b) Magnetic circuit

(a) Centralized coil (b) Distributed coil Fig. 4 Two types of arrangement of planar coils TABLE I MEASUREMENT OF THE K FOR DIFFERENT WINDING ARRANGEMENT Measured coil core Weight(g) L(mm) k Centralized Planar U43 0.39 (Planar E43/10/28 59 34.7 Distributed 0.46 without center leg) Test condition: Np:Ns=25:25, g=10mm, fs=300kHz but different winding arrangements is shown in Tab. 1.

achieve higher coupling coefficient, smaller size and lighter weight simultaneously. A new contactless transformer for a 60W CETS is designed. The new Fig. 3. Improved transformer has a coupling Transformer Core coefficient improvement of up to 0.6 at a gap length of 10mm, a core weight reduction of down to 60g, and an associated maximum efficiency improvement of 2.5%. The consistency of the coupling coefficient obtained from calculation and measurement verifies the validity of the analysis. The improvement of the efficiency of the CETS testifies the effectiveness of the optimized transformer. II. A. IMPROVED CONTACTLESS TRANSFORMER

Core shape The contactless transformer structure and its equivalent magnetic circuit shown in Fig.2.(a) have been proposed by T. H. Nishimura in 1994[17]. To simplify the analysis, the equivalent magnetic circuit as shown in Fig.2.(b) is proposed under the conditions of the symmetrical transformer structure and secondary being open circuit. Where F equals Ni, Ra and RL are the correspondence reluctance. It is pointed out in [17] that the value of coupling coefficient k depends on the ratio of (g / Lc). The larger the parameter Lc, the higher is the k with g fixed. In order to obtain a higher k, a planar core (usually with larger Lc comparing to other core shapes) without center leg is proposed as shown in Fig.3, which has a smaller ratio of (g/Lc), so as to reduce the weight. It should be noted that the inner distance (L) between two magnetic legs has predominant influence to the reluctance RL rather than the center distance Lc, we use L to illustrate the behavior of the contactless transformer in this paper. B. Winding arrangement For planar core, the planar winding is the optimal choice to lower the leakage inductance[18]. There are two types of winding arrangement as shown in Fig.4: centralized coil and distributed coil. The experimental measurement as shown in Tab. 1 indicates that the distributed coil for the transformer gives higher k. The electromagnetic field simulation results with different winding arrangement are as shown in Fig.5 (at ip=3A, is=0A). It can be observed that for the centralized coil, the flux line excited by the primary current can get a direct closure though the space between the windings in the center of the core window, lowering the k. Therefore,

distributed coil of the transformer shoud be adopted in the improved transformer. III. IMPROVED MAGNETIC RELUCTANCE CIRCUIT Limitation of the magnetic reluctance circuit in [17] According to the analysis in [17], the magnetic reluctance circuit of the improved transformer structure is shown in Fig.6, where F1=F2=Ni/2. Similar to [17], the expression of the k can be deduced as (1). ( F1 + F2 ) 2 Ra 1 k= (1) ( F1 + F2 ) 2 Ra + ( F1 + F2 ) RL (2 g / L) + 1 However, equation (1) cannot explain some of the experimental results. (1). Planar U43 has the L of 34.7mm, larger than that of Planar E64 in [15] (21.8mm), while having lower k (0.46) than that of Planar E64 (0.532). (2). PlanarU64 (PlanarE64/10/50 without center leg) has L of 53.8mm, much larger than that of planar U43, while having slightly higher k (0.48) than that of planar U43 (0.46). (3). The k value calculated using (1) is much higher than that measured. The disagreement between the analysis and the experimental results indicates that the magnetic reluctance circuit shown in Fig.6 is not accurate enough to describe the improved transformer; as well as predicting k.
Fig. 6 Magnetic circuit

(a) Centralized coil (b) Distributed coil Fig. 5 Electromagnetic field simulation results

A.

B. Proposed magnetic reluctance circuit Similar to [17], the analysis in this paper is under the

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TABLE II FLUX-COUPLING RELATIONSHIP OF THE TRANSFORMER Fully Partially Leakage L coupled MF coupled MP Primary N N N1 windings Secondary N N2 0 windings Fig. 7 Separation of the magnetic flux
RL2 RL 3 RM 2 RM1 RL1 RM1 RL2 RL3 RM 2

For a transformer with the turns ratio of 1:1, Lm=M. Substituting Lm=M in (2) gives
k= M Ll1 + M

(3)

A.

Fig. 8

Definition of the reluctance

Expression of inductance and k Different from traditional transformers, a considerable part of flux of the contactless transformer is not concentrated in the core, resulting in the complexity of the flux-coupling relationship. It might as well to make such assumption about the flux-coupling relationship as shown in Tab.2. Based on the flux-coupling relationship defined in Tab.2, the concept of M and Ll1 gives
Mi = N MF + N 2 MP = Ll1i = N1 L = N1 ( N 2 i NN 2i + = ( M F + M P )i 2 RM 1 2 RM 2

Ni Ni + ) 2 RL3 RL1 + 2 RL 2
N1 N

(4)

Fig. 9

Magnetic reluctance circuit with better accurancy

Defining
= =
N2 N

conditions of the symmetrical transformer structure and secondary being open circuit, so as to simplify the analysis. According to the coupling characteristics, the simulated magnetic field can be separated into several areas, as shown in Fig. 7. Part 1: Leakage flux L (area 1A and 1B). Excited by the primary current, not coupled by the secondary. L=1A+1B, where 1A and 1B are leakage flux in area 1A and 1B. Part 2: Partially coupled flux MP (area 2). Excited by the primary current, coupled by the partial windings of the secondary. Part 3: Fully coupled flux MF (area 3). Excited by the primary current, coupled by all the secondary windings. Based on the proposed classifications of flux, the corresponding reluctance is defined as shown in Fig.8. As a result, the magnetic reluctance circuit as shown in Fig.9 can be acquired. IV. CALCULATION OF THE RELUCTANCES AND K Like traditional transformer, coupling coefficient of the contactless transformer can be expressed with coupled inductance M and self inductance of the transformer windings. The symmetrical construction of the transformer means Lp=Ls, turns ratio is 1:1. Thus
k= M LP LS = M LP

(5)

The inductances of the trasnformer are given by the following expressions, N2 N2 N2 M = MF + MP MF = MP = Ll1 = (6)
RMF RMP RL

where RMF, RMP and RL are the equivalent reluctance of the flux path for MF, MP and L respectively.
RMF = 2 RM 1 RMP = 2 RM 2

(7)

RL = 2 RL 3 ( RL1 + 2 RL 2 )

Substituting (5), (6), (7) into (3) gives

k= 2 RL 3 = RMF N2 N2 + MF + MP 2 RM 1 2 RM 2 = N2 N2 N 2 MF + MP + L + + ( RL1 + 2 RL 2 ) 2RM 1 2RM 2 1 ( RMP / ) +1 RL /

(8)

(2)

Partition of flux tube and reluctance calculation To calculate of the reluctance of the reluctance circuit, it is necessary to analyze the trajectory of the flux. That means, to build the magnetic flux tubes for the transformer. Fig.10 illustrates the results. Leakage flux 1A, lies in the core window and flows through RL1 and RL2 as shown in Fig.10 (a). Flux path for RL1 has a cross sectional shape of ellipse, whose major axis and minor axis are L1 and 2g respectively. Flux path for RL2

B.

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has a cross sectional shape of rectangle of which the width is (L1-e)/2 and the height is d. Leakage flux 1B, surrounds the core and flows through RL3. Its flux tube has a cross sectional shape of circle as shown in Fig.10 (b). Adopting distributed coil, area of 1B keeps certain distance away from core. The effect of the gap change on 1B and RL3 can be ignored. Fully coupled flux MF and partially coupled flux MP. MF flows through RM1 and MP flows through RM2. As Fig.10(b) shows, the flux tube corresponding with MF is consist of two parts: the rectangular section tube of reluctance RM1_1 and semicircle section tube of reluctance RM1_2. Similarly, MP consists of two parts: the hollow-semicircle section tube of reluctance RM2_1 and trapezoid section tube of reluctance RM2_2. And thus, RM1=RM1_1||RM1_2, RM2=RM2_1||RM2_2. Five steps are taken to calculate reluctances according to the partition of the flux tubes. Step 1: Simplify the structure of transformer to get the flux tubes. Neglecting the uneven distribution of the flux in the direction of core width W, the practical transformer, as shown in Fig.11(a), can be simplified to Fig.11(b). Thus, the depth of the flux tubes are limited to be W. The flux tubes are shown in Tab.3. Step 2: Determine the geometric parameter of flux tubes. As shown in Tab.4, parameters L, c, d, and f are core geometric dimensions. From the simulation results shown in Fig.7 and Fig.10, it is easy to figure out the relationship between a, b and L, L1, as shown in Tab.4. Thus, determination of L1 and e in Fig.10.(a) becomes critical.

reluctance section shape sketch reluctance section shape

TABLE III FLUX TUBES FOR THE RELUCTANCE RM1_1&RL2 RM1_2 rectangle semicircle

RM2_1 Semi-cylinder

RM2_2 trapezoid

RL1 ellipse
W

RL3 round

sketch
r

Fig. 10 (a) Central core window

Fig. 10 (b) Regions near magnetic leg

An empirical formula has been achieved through emulation of the contactless transformer with planar U core. It turns out that L1 and e have no concern with core dimensions, but only changing with air gap g. L1 ( g ) = 0.24 g 0.4 0.0098 (9) It should be noted that, parameter r is canceled out in the solution procedure of reluctance RL3. And hence, there is no need to discuss r. Step 3: After determining the dimensions of the flux tubes, the reluctance for different flux tubes can be calculated. Examples are provided in the appendix. Step 4: Considering the difference of the flux tube depth W with that of practical transformer, the shape correction coefficient should be introduced. That means the computed result achieved from step 3, must multiply by the appropriate correction coefficient. It can be seen from Fig.10 and Fig.11 that flux tubes of RM1_2, RM2_1 and RL3 have been shorten to W in depth after simplifying. To ensure the equality of flux, the modified factor should be determined according to the ratio of W to average circumference of different magnetic flux area. Structure simplifying has no TABLE IV effect on other reluctances. VALLUES IN FIG.10 Step 5: The existences of Parameter Valuemm and indicate that the leakage L Core parameter (34.7) and partially coupled flux is not c Core parameter (10) fully coupled with all the d Core parameter (5.4) windings, and thus the f Core parameter (4.25) calculated reluctances in step 4 W Core parameter (4.25) doesnt satisfy the magnetic a(g) (L-L1)/2 reluctance circuit in Fig.9. b L/2 Defining rL1, rL2 and rL3 as the L1(g) 240g0.4-4.9 calculated results in step 4, e 5 associating with L. Based on Notethe value in the bracket is the Ohm's law,
of planar U43 core.

Fig. 11(a) Practical transformer

Fig. 11(b) Simplified transformer for reluctance calculation

L = =

2 RL3 2 [ rL 3

Ni N1i = ( RL1 + 2 RL 2 ) 2rL 3 ( rL1 + 2rL 2 ) Ni ( rL1 + 2rL 2 ) ] /

(10)

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Reluctance
RM1=RM1_1 RM1_2

TABLE V RELUCTANCE CALCULATION FORMULA Shape Formula Correction factor rectangle semicircle Semicylinder trapezoid
RM 1_1 ( g ) = g

0Wf

1
kc = (1.5ln( g ) + 11)

RM 1_ 2 ( g ) =

1 0.26 0W

1+ f

RM2=RM2_1 RM2_2

RM 1_1 ( g ) =

( + 1)
2 0W

g c

km1 = 2.13

Fig. 14(a) Optimization of core length(front view)

Fig. 14(b) Optimization of core width(bottom view)

RM 2 _ 2 ( g ) =

2( g + 2d )

0 (a + b)W

1
1

RL1 RL2 RL3

0.65 0.6

ellipse rectangle circle

RL 1 =

[1.5(

L1 ( g ) g gL1 ( g ) + ) ] 4 2 8 L (g) + 2g 2 0W ( 1 ) 4

RL 2 =

0W [ L1 ( g ) e ]

2d

(a) unidirectional rectangle

(b) bidirectional rectangle

RL 3 = 0W

km 2 = 2.03
1

0.55 0.5 0.45 0.4 4 6 8 10 g(mm) 12 14

(c) round (d) polygon Fig.15 Planar U core with extension leg

Fig. 12 Values of and

V. OPTIMIZATION OF THE TRANSFORMER STRUCTURE Based on the analyzed results of reluctance and k, the optimization approach to obtain higher k, smaler size and lighter weight for the contactless transformer can be investigated. Transformer Optimization Methods Increasing the proportion of the coupled flux is the key to improve the k. Besides, the larger ratio of the fully coupled flux, the higher is the coupling coefficient. Hence RMF and RMP should be reduced, at the same time increasing RL1, RL2 and RL3.The optimizing method can be fund by the analyzing the effect of the core dimensions on k. Equation (1) discloses that when L<2g, and k<0.5, k cannot be optimized to be higher than that of [15] at the same air gap; when L>2g, according to Tab.5, enlarging L can only reduce the trapezoid shape reluctance (RM2_2), increasing core size and weight at the same time. Since RM2_2 is related to partially coupled flux, the effect of enlarging L on k is not significant. Shift to enlarge f instead of L, as Fig.14(a) shows. It can be seen from Fig.5 that enlarging f will reduce RM2_2, increasing the portion of fully coupled flux. It is obvious that although the cores in Fig.14(a) have the same weight and volume, the one with larger f has higher k. Therefore, when L>2g, enlarging f is recommended Tab.5 illustrates that all the reluctances reduce as parameter W increases. To increase the coupled flux and to decrease the leakage flux at the same time, the W for different region of the core can be different, as shown in Fig 14(b). As mentioned above, distributed coil should be adopted to prevent a direct closure of leakage flux though the space A.

It can be seen from (10) that, 1/ should be introduced as the winding correction coefficient for the calculation of RL1, RL2 and RL3. The ultimate formulas for the reluctances are list in Tab.5. Calculation of inductance and k It can be seen from (6), (8), and Tab.5 that determination of and is the key of the calculation of inductances and k. In this paper, and are solved by means of simulation with Ansoft 2D. Substituting the reluctances values calculated in step 3, and the inductances obtained by 2D magnetic field simulation, into (6), and can be calculated. The value of and of planar U43 (with distributed coil, Np=Ns=25) is shown in Fig.12. Using the obtained value of and , the reluctances, inductances and k can be then calculated. Fig. 13 illustrates that the the calculated value agrees with the measured value very well, verifying the high acurracy of the caiculation method. C.

(a) k (b) M, Ll1 Fig. 13 Comparisions of calculated and measured parameter

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TABLE VI COMPARISON OF EXPERIMENTAL RESULTS Weight Measured Parameters Photo of the primary (g) k Transformer in [15] Planar E 64/10/50 Np:Ns=19:17 Planar U 43 Model 2 Np:Ns =25:25 Fig. 17 Magnetic flux line Reconstructive core with Novel contactless PlanarE32/6/20 transformer Np:Ns =24:20 TABLE VII COMPARISON OF EFFICIENCY Input Output Load voltage voltage 3560V 24V 9.648 59 0.46

122

0.53

Fig. 16 Core structure

60

0.60

Air gap 10mm Fig. 18 Coupling coefficient of novel transformer

Power 1260W

between the windings in the center of the core window. B. Optimized transformer From the above analysis, a novel transformer structure with planar U core with extension leg is proposed as shown in Fig.15. The extension leg can be a shape of rectangle, circle or polygon. And windings encircling the extension legs are split into two parts and kept in distributed arrangement. As the extension structure enlarges bottom area of magnetic legs, reduces the reluctance of coupled flux, especially RMF, the coupling coefficient can be improved greatly. At the same time, size and weight of the core keep low since the extension part limited at the bottom of the core. For the novel transformer, the parameter L should be slightly larger than 2g, in order to maximize the portion of MF, so as to increase k and decrease the size and weight of the core. VI. SIMULATION AND EXPERIMENTAL RESULTS A contactless transformer with optimized core is made for 60W CETS. The core structure is shown in Fig.16 and its turn ratio is Np:Ns =24:20. Magnetic flux simulation result of the optimized transformer at 300kHz, g=10mm, ip=3A is shown in Fig.17. Calculating , , according to the Tab.5, (7), and (8), the k of the novel contactless transformer can be deduced as shown in Fig.18. The nearly perfect agreement verifies the correctness of the analysis. Comparisons of several contactless transformers are shown in Tab. 6. The novel transformer has the coupling coefficient improvement of up to 0.6 at the gap

(a) Effiency at different Vin @60Woutput,

(b) Effiency at different Io @35Vinput Fig. 19 Comparisons of efficiency

length of 10mm. The core weight reduction is 60g. A contactless power converter for artificial hearts of 60W has been built according to the specifications given in Tab.7. Comparisons of efficiency to the converter in [14] are shown in Fig. 19. It can be readily seen that with the new transformer, the efficiency improvement at full load is about 0.5%, and the maximum efficiency improvement is about 2.5%. VII. CONCLUSION

Contactless transformer in the CETS has been studied in this paper. A novel core structure and coil arrangement for improving transformer coupling coefficient, size and weight

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is presented. A magnetic circuit has been formulated and the magnetic flux is classified. Reluctances and coupling coefficient is calculated by clarifying the flux tube. The optimization of the transformer for higher k and lighter weight is discussed. Based on the analysis, novel structure of the contactless transformer is proposed and developed. We have succeeded in obtaining a coupling coefficient improvement of up to 0.6 and the cores weight reduction down to 60g for a gap length of 10 mm. At last, a 60W contactless power regulator is built. With the novel transformer, the maximum efficiency improvement is about 2.5%. APPENDIX Flux tubes shown in Fig.10 calculated based on Eq.10.
RM = lav

[9]

Chwei-Sen Wang, Oskar H. Stielau, and Grant A. Covic, Design considerations for a contactless electric vehicle battery charger, IEEE Transactions on industrial electronics, vol.52, No.5, October 2005.

0 Aav

(10)

where lav is the average length of magnetic path and Aav is the average area of magnetic path. Take RL1 for example, according to the elliptical circumference formula, the average length of magnetic path equals to lav = 1.5 (
L1 ( g ) g gL1 ( g ) + ) , and 4 2 8
g+ 2 L1 2W .

the average area of Similar approach is

magnetic path equals to Aav =

taken to calculate other reluctances. REFERENCES

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