Design and analysis of a multi-segment multi-permeability core for EV wireless charging with enhanced efficiency and thermal performances

Yibo Wang, C.Q. Jiang, Liping Mo, Xiaosheng Wang, Weisheng Guo and Ben Zhang

Applied Energy, 2024, vol. 375, issue C, No S0306261924015642

Abstract: This paper introduces a novel design for a soft magnetic core (SMC) using laminated nanocrystalline flake ribbons (NFR) to improve the efficiency and thermal performance of EV wireless charging. The nanocrystalline ribbons, with configurable permeability, offer high flexibility, high power density, and low core loss for the vehicle assembly (VA) side in inductive power transfer (IPT) applications. However, the lamination structure and high conductivity of the material present challenges in analyzing loss characteristics. This paper systematically addresses these issues. Firstly, NFR materials with varying permeabilities are analyzed using traditional toroidal measurements. Next, the flux distribution and eddy current losses due to norm flux in IPT are considered. Finite element method (FEM) simulations are then utilized to illustrate the impact of additional eddy current losses and the imbalance caused by the lamination structure. A multi-segment, multi-permeability core structure is proposed to optimize core loss, coupling coefficient, and flux density distributions. Finally, experiments are conducted to assess the new design's performance. The proposed structure achieves a DC-DC efficiency of 95.68% at 12.78 kW output power and maintains optimized efficiency even with aluminum shielding. Additionally, improvements in temperature distribution uniformity and thermal stability are observed, demonstrating superior performance compared to traditional ferrites.

Keywords: Wireless power transfer; Electromagnetic energy conversion; Soft magnetic material (search for similar items in EconPapers)
Date: 2024
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DOI: 10.1016/j.apenergy.2024.124181

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