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

Author

Listed:
  • 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)

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.

Suggested Citation

  • Jinhai Jiang & Yu Lan & Ziming Zhang & Xingjian Zhou & Kai Song, 2022. "Thermal Estimation and Thermal Design for Coupling Coils of 6.6 kW Wireless Electric Vehicle Charging System," Energies, MDPI, vol. 15(18), pages 1-17, September.
    • Handle: RePEc:gam:jeners:v:15:y:2022:i:18:p:6797-:d:917360
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    References listed on IDEAS

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    1. Bragadeshwaran Ashok & Chidambaram Kannan & Byron Mason & Sathiaseelan Denis Ashok & Vairavasundaram Indragandhi & Darsh Patel & Atharva Sanjay Wagh & Arnav Jain & Chellapan Kavitha, 2022. "Towards Safer and Smarter Design for Lithium-Ion-Battery-Powered Electric Vehicles: A Comprehensive Review on Control Strategy Architecture of Battery Management System," Energies, MDPI, vol. 15(12), pages 1-44, June.
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    Cited by:

    1. Adrian Chmielewski & Piotr Piórkowski & Jakub Możaryn & Stepan Ozana, 2023. "Sustainable Development of Operational Infrastructure for Electric Vehicles: A Case Study for Poland," Energies, MDPI, vol. 16(11), pages 1-43, June.

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