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Magnetic Gear Wireless Power Transfer System: Prototype and Electric Vehicle Charging

Author

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  • Caleb Dunlap

    (Center for Energy Systems Research, Tennessee Tech University, 1020 Stadium Dr., Cookeville, TN 38505, USA
    Department of Electrical and Computer Engineering, Tennessee Tech University, 115 W. Tenth St., Cookeville, TN 38505, USA)

  • Charles W. Van Neste

    (Department of Electrical and Computer Engineering, Tennessee Tech University, 115 W. Tenth St., Cookeville, TN 38505, USA)

Abstract

This paper investigates the potential of a magnetic gear wireless power transfer (WPT) system for electric vehicle (EV) charging, with the advantages of low-frequency operation, low foreign object interference, low electromagnetic emissions, and high misalignment tolerance. The study explores the novel impact of Halbach arrays that enhance the flux density in desirable locations while decreasing the flux in undesirable locations, which provides the benefit of decreased foreign object attraction. The initial prototype results demonstrate that the Halbach system can transmit approximately 34.65 W with a transfer efficiency of 64% across a gap of 104 mm. The Halbach system is experimentally compared to a conventional magnet arrangement, which achieved a maximum power transfer of 88 W over 104 mm. The Halbach system is applied to a personal mobility EV to enable wireless charging at low frequency. The axial design of this WPT system has the unique benefit of a 360° radial coupling angle that maintains constant, near-maximum levels of power transfer and efficiency. This full circle coupling angle allows the personal EV to park in any direct vicinity of the charger and achieve the same level of charging given a certain distance. This study delivers important contributions to advancing a low-frequency wireless EV charging technology based on magnetic gears, that sets the stage for future innovations focused on optimizing efficiency, increasing safety, and simplifying the charging process.

Suggested Citation

  • Caleb Dunlap & Charles W. Van Neste, 2025. "Magnetic Gear Wireless Power Transfer System: Prototype and Electric Vehicle Charging," Energies, MDPI, vol. 18(3), pages 1-18, January.
    • Handle: RePEc:gam:jeners:v:18:y:2025:i:3:p:532-:d:1575878
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    References listed on IDEAS

    as
    1. Gerardo Ruiz-Ponce & Marco A. Arjona & Concepcion Hernandez & Rafael Escarela-Perez, 2023. "A Review of Magnetic Gear Technologies Used in Mechanical Power Transmission," Energies, MDPI, vol. 16(4), pages 1-32, February.
    2. Kai Song & Yu Lan & Xian Zhang & Jinhai Jiang & Chuanyu Sun & Guang Yang & Fengshuo Yang & Hao Lan, 2023. "A Review on Interoperability of Wireless Charging Systems for Electric Vehicles," Energies, MDPI, vol. 16(4), pages 1-22, February.
    3. Chunhua Liu & K. T. Chau, 2014. "Electromagnetic Design of a New Electrically Controlled Magnetic Variable-Speed Gearing Machine," Energies, MDPI, vol. 7(3), pages 1-16, March.
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