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Design and Implementation of an Inductive Power Transfer System for Wireless Charging of Future Electric Transportation

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Design and Implementation of an Inductive Power Transfer System for Wireless Charging of Future Electric Transportation DESIGN AND IMPLEMENTATION OF AN INDUCTIVE POWER TRANSFER SYSTEM FOR WIRELESS CHARGING OF FUTURE ELECTRIC TRANSPORTATION by Kunwar Aditya A Thesis Submitted to the Faculty of Graduate Studies through the Department of Electrical, Computer and Software Engineering in Partial Fulfillment of the Requirements for the Degree of Doctor of Philosophy at the University of Ontario Institute of Technology Oshawa, Ontario, Canada August 2016 © Kunwar Aditya, 2016 Design and implementation of an inductive power transfer system for wireless charging of future electric transportation By Kunwar Aditya APPROVED BY SUPERVISORY COMMITTEE: Dr. Srdjan Lucik, External Examiner (Department of Electrical and Computer Engineering, North Carolina State University) Dr. Sheldon S. Williamson, Thesis Supervisor (Department of Electrical, Computer and Software Engineering, UOIT, Oshawa) Dr. Vijay Sood, Internal Examiner (Department of Electrical, Computer and Software Engineering, UOIT, Oshawa) Dr. Walid M. Ibrahim, Internal Examiner (Department of Electrical, Computer and Software Engineering, UOIT, Oshawa) Dr. Greg Rohrauer, External to Program (Department of Automotive, Mechanical and Manufacturing Engineering, UOIT, Oshawa) Dr. Ying Wang, Committee Chair (Department of Electrical, Computer and Software Engineering, UOIT, Oshawa) [August 30, 2016] ii Abstract Design and implementation of an inductive power transfer system for wireless charging of future electric transportation Kunwar Aditya, Ph.D. The University of Ontario Institute of Technology, 2016 The motivation of this thesis was to formulate clear design guidelines for fabrication and control of an efficient series-series resonant inductive power transfer (SS-RIPT) system for electric vehicle battery charging application. In meeting this objective, several critical deficiencies about the field of RIPT based EV chargers specific to stationary charging have been solved. Firstly, to increase the tolerance to misalignments, use of an unsymmetrical coil pair for the charger has been proposed. An unsymmetrical coil pair, in which the outer diameter of the primary and the secondary coils are kept equal, whereas the inner diameter of the secondary is kept larger compared to the primary counterpart gives the best performance in misalignment conditions. By employing this unsymmetrical coil-pair, a charging pad which shows the horizontal tolerance to misalignment equal to 71% of the pad diameter has been presented. Secondly, a very simple yet novel analytical design procedure has been submitted, adopting which, eliminates the bifurcation issue for the entire range of load and coupling variation and therefore requires no sophisticated control. Finally, a simplified mathematical model of SS-RIPT system has been proposed for primary side control of output voltage and current. All the proposed theories and analysis have been verified by a 3.6 kW prototype of the SS-RIPT based charger fabricated in the lab. A DC-DC efficiency of 91% for rated load condition is achieved for the designed charger. For partial load conditions (less than 50% of the rated load), the efficiency is 87%. iii Acknowledgements I express my deepest sense of gratitude to my supervisor Dr. Sheldon S. Williamson for accepting me as his Research Assistant and for his guidance during the course of this research. I am highly indebted to him for the financial support during my tenure as his Research Assistant. I would like to thank him for the supervision, trust and time that I received during this research that proved very useful for increasing my research capabilities and increasing my knowledge of power electronics. I owe the successful realization of this work to the financial support from Dr. Williamson through NSERC and Transport Canada, as well as the teaching assistantship provided by the University Of Ontario Institute Of Technology, Oshawa, Ontario. Many thanks to Dr. Najath Abdul Azeez, Post-doctoral Fellow at UOIT for his timely support on the procurement of components and pieces of equipment requested by me. I also acknowledge the help and encouragement from my colleagues in the STEER group. I would also like to acknowledge the utilization of facilities available at the Department of Electrical and Computer Engineering, Concordia University, Montreal, Quebec, where I pursued the first year of my Ph.D. research under the supervision of Dr. Sheldon Williamson. Last, but not least, I am grateful to my parents for allowing me to study abroad and carry out the research, as well as for their love and moral support. iv Table of Contents Abstract .................................................................................................................................................. iii Acknowledgements .................................................................................................................................iv List of Figures .........................................................................................................................................ix List of Tables ........................................................................................................................................ xiii List of Symbols...................................................................................................................................... xiv Introduction ..................................................................................................................... 17 1.1 Rationale for Adopting Wireless Charging system for EVs ........................................ 18 1.2 A Brief History of Development of RIPT System for EV Charging ........................... 20 1.3 Working Principle and Components of RIPT System ................................................. 23 1.4 Wireless Charging Standards for Electric Vehicle ...................................................... 27 1.5 Research Goals and Objectives ...................................................................................... 29 Design Considerations for Resonant Inductive Link ................................................... 33 2.1 Brief Overview of Different Coil Shapes Employed In Wireless Charger ................. 33 2.2 Electrical Equivalent Circuit for Series-Series Compensated RIPT System ............. 36 2.2.1 Quality Factor of an SS-RIPT System ............................................................... 38 2.2.2 Bifurcation Phenomena In an SS-RIPT System................................................ 41 2.3 Calculation of Electrical Parameters for Bifurcation Free Operation ....................... 47 2.4 Analytical Design of Archimedean Spiral Coils ........................................................... 49 2.4.1 Analytical Model of Self-Inductance of Coils .................................................... 50 2.4.2 Analytical Model of Mutual Inductance between Coils.................................... 52 2.5 Finding Coil-Pair Least Sensitive to Misalignment...................................................... 54 2.5.1 Calculation of Electrical Parameters for 500 W setup. .................................... 55 2.5.2 Calculation of Geometric Parameters for 500 W setup. ................................... 60 2.5.3 Verification of Analytical Expressions ............................................................... 63 2.5.4 Mutual Inductance Profile of Coil-Pairs............................................................ 67 2.6 Summary of Chapter 2 ................................................................................................... 72 Design of 3.6 kW Wireless Charger............................................................................... 73 v 3.1 Calculation of Electrical Parameters ............................................................................ 73 3.2 Design of Litz Wire for the Coils ................................................................................... 74 3.3 Fabrication of Coils for 3.6 kW Charger ...................................................................... 76 3.4 Addition of Ferrites to the Fabricated Coils ................................................................. 77 3.5 Verification of Designed Pads ........................................................................................ 80 3.5.1 Verification of Magnetic Saturation in Ferrites ................................................ 80 3.5.2 Verification of Bifurcation Free Design ............................................................. 82 3.6 Sensitivity Analysis of Designed Pads ........................................................................... 84 3.7 Summary of Chapter 3 ................................................................................................... 88 Mathematical Model and Controller Design ................................................................ 89 4.1 A Reduced Dynamic Model for an SS-RIPT system .................................................... 90 4.2 Derivation of Small-Signal Model from Reduced Dynamic Model ............................ 93 4.3 Piecewise-Linear Model of Li-Ion Battery Pack ........................................................ 100 4.4 Selecting the Compensation Capacitors for ZVS Tuning .......................................... 103 4.5 Design of Voltage Control Loop .................................................................................. 107 4.5.1 Bode Plot of Open-Loop System ....................................................................... 107 4.5.2 Derivation
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