Production Concepts for Inductive Power Transfer Systems for Vehicles

Alexander Kuehl (), Maximilian Kneidl, Johannes Seefried, Michael Masuch, Michael Weigelt and Joerg Franke
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Alexander Kuehl: Institute FAPS, Friedrich-Alexander-Universität Erlangen-Nürnberg, 91058 Erlangen, Germany
Maximilian Kneidl: Institute FAPS, Friedrich-Alexander-Universität Erlangen-Nürnberg, 91058 Erlangen, Germany
Johannes Seefried: Institute FAPS, Friedrich-Alexander-Universität Erlangen-Nürnberg, 91058 Erlangen, Germany
Michael Masuch: Institute FAPS, Friedrich-Alexander-Universität Erlangen-Nürnberg, 91058 Erlangen, Germany
Michael Weigelt: Institute FAPS, Friedrich-Alexander-Universität Erlangen-Nürnberg, 91058 Erlangen, Germany
Joerg Franke: Institute FAPS, Friedrich-Alexander-Universität Erlangen-Nürnberg, 91058 Erlangen, Germany

Energies, 2022, vol. 15, issue 21, 1-12

Abstract: The option of wireless energy transmission in electric vehicles can become the main market driver for electric vehicles due to its distinct advantages, such as range, weight, or costs, over conventional conductive charging solutions. In addition to the great potential, which different research work and realized systems have already shown, there are new requirements for the associated production networks in the automotive industry which must be addressed at an early stage. Furthermore, no solutions currently exist for the industrial production of these components. This paper presents the main components for the feasibility of wireless power transmission in electric vehicles. In addition, the required value chains and processes for the new components of the inductive power transfer systems, and the final assembly for induction coils, which has been developed at the FAU, will be presented. These include the developing of a winding process on a 15-axis special machine, ultrasonic crimping of the litz wire ends, and vacuum potting.

Keywords: charging automation; electric vehicles (EVs); wireless charging; wireless power transfer (WPT); production; automation; inductive power transfer (IPT); manufacturing (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
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