Thermal Estimation and Thermal Design for Coupling Coils of 6.6 kW Wireless Electric Vehicle Charging System

Jinhai Jiang, Yu Lan (), Ziming Zhang, Xingjian Zhou and Kai Song ()
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Jinhai Jiang: School of Electrical Engineering and Automation, Harbin Institute of Technology, Harbin 150001, China
Yu Lan: School of Electrical Engineering and Automation, Harbin Institute of Technology, Harbin 150001, China
Ziming Zhang: School of Electrical Engineering and Automation, Harbin Institute of Technology, Harbin 150001, China
Xingjian Zhou: School of Electrical Engineering and Automation, Harbin Institute of Technology, Harbin 150001, China
Kai Song: School of Electrical Engineering and Automation, Harbin Institute of Technology, Harbin 150001, China

Energies, 2022, vol. 15, issue 18, 1-17

Abstract: Wireless electric vehicle charging technology is developing in the direction of high power levels. However, more generated heat brought by higher power will accelerate the system’s aging and can even lead to damage. An excellent thermal design for the magnetic coupler can reduce each part’s maximum temperature, ensuring long-term operation reliability. Therefore, in this article, the magnetic coupler’s thermal estimation and design are studied based on a 6.6 kW wireless electric vehicle charging system. First, the calculation method of internal resistance of a litz coil, core loss, and eddy current loss of a shielding aluminum plate are studied. Considering the influence of thermal fields on material properties, each part’s power loss calculation formula is further modified to improve the accuracy. After that, heat dissipation research is carried out. The heat dissipation measures, such as filling the surface of the shielding aluminum plate with thermal conductive silicone grease, are proposed. Finally, the effectiveness of the heat dissipation measures is verified by simulation and experiments. The experiment shows that the error between the power loss value of each part calculated by simulation and measured by the experiment is less than 15%, and the maximum temperature of the magnetic coupler is controlled below 80 °C.

Keywords: wireless electric vehicle charging system; magnetic coupler; loss calculation; thermal simulation (search for similar items in EconPapers)
JEL-codes: Q Q0 Q4 Q40 Q41 Q42 Q43 Q47 Q48 Q49 (search for similar items in EconPapers)
Date: 2022
References: View references in EconPapers View complete reference list from CitEc
Citations: View citations in EconPapers (1)

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