Multiphysics Investigation of an UltrathinVehicular Wireless Power Transfer Module for Electric Vehicles

Martin Helwig, Steve Zimmer, Peter Lucas, Anja Winkler and Niels Modler
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Martin Helwig: Institut für Leichtbau und Kunststofftechnik, Technische Universität Dresden, 01307 Dresden, Germany
Steve Zimmer: Mercedes-Benz AG, 059/H515, 71032 Böblingen, Germany
Peter Lucas: Sächsisches Staatsministerium für Wirtschaft, Arbeit und Verkehr, 01097 Dresden, Germany
Anja Winkler: Institut für Leichtbau und Kunststofftechnik, Technische Universität Dresden, 01307 Dresden, Germany
Niels Modler: Institut für Leichtbau und Kunststofftechnik, Technische Universität Dresden, 01307 Dresden, Germany

Sustainability, 2021, vol. 13, issue 17, 1-20

Abstract: The functional and spatial integration of a wireless power transfer system (WPTS) into electric vehicles is a challenging task, due to complex multiphysical interactions and strict constraints such as installation space limitations or shielding requirements. This paper presents an electromagnetic–thermal investigation of a novel design approach for an ultrathin onboard receiver unit for a WPTS, comprising the spatial and functional integration of the receiver coil, ferromagnetic sheet and metal mesh wire into a vehicular underbody cover. To supplement the complex design process, two-way coupled electromagnetic–thermal simulation models were developed. This included the systematic and consecutive modelling, as well as experimental validation of the temperature- and frequency-dependent material properties at the component, module and system level. The proposed integral design combined with external power electronics resulted in a module height of only 15 mm . The module achieved a power of up to 7.2 kW at a transmission frequency of f 0 = 85 kHz with a maximum efficiency of 92% over a transmission distance of 110 mm to 160 mm . The proposed simulations showed very good consistency with the experimental validation on all levels. Thus, the performed studies provide a significant contribution to coupled electromagnetic and thermal design wireless power transfer systems.

Keywords: electromagnetic–thermal simulation; multiphysical testing; lightweight design; wireless power transfer; inductive charging; electric vehicle (search for similar items in EconPapers)
JEL-codes: O13 Q Q0 Q2 Q3 Q5 Q56 (search for similar items in EconPapers)
Date: 2021
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Persistent link: https://EconPapers.repec.org/RePEc:gam:jsusta:v:13:y:2021:i:17:p:9785-:d:626303

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