INDUCTIVE POWER TRANSFER CHARGING STATION FOR STATIC AND DYNAMIC CHARGE OF ELECTRICAL VEHICLES Presented by: Anton Tonchev, Technical University - Gabrovo UNITECH 2014 Prof.Raycho Ilarionov, assoc prof. Nikolay Madzharov
Innovative fast charging solution for electric vehicles The main task of the project is development of High Power Contactless Charging System for Electric Vehicles. The system must have efficiency greater than 85 percent and to provide conditions for accelerated charging of the vehicle.
Innovative fast charging solution for electric vehicles Starting date: 01/10/2012 End date:30/09/2015 PARTNERS IN THE PROJECT FastInCharge is lead by a consortium of 9 partners from 6 countries: France, Bulgaria, Italy, Spain, Greece and Slovakia. The list includes : 1.Companies, specialized in charging infrastructure for EV 2.Automotive engineering companies 3.Research organizations 4.Specialists of power electronics and energy management systems 5.Project management organizations
Innovative fast charging solution for electric vehicles Starting date: 01/10/2012 End date:30/09/2015 ALL PARTNERS IN THE PROJECT DOUAISIENNE DE BASSE TENSION SAS ("DBT") France www.dbt.fr EUROQUALITY ("EQY") France www.euroquality.fr TECHNICAL UNIVERSITY GABROVO ("TUG") Bulgaria www.tugab.bg AUTOMOBILOVY KLASTER ("ACWS") Slovakia www.autoklaster.sk BATZ SOCIEDAD COOPERATIVA ("BATZ") Spain www.batz.com COMMUNE DE DOUAI ("DOUAI") France www.ville-douai.fr INSTITUTE OF COMMUNICATION AND COMPUTER SYSTEMS ("ICCS") Greece www.iccs.gr FUNDACION TECNALIA RESEARCH & INNOVATION ("TECNALIA") Spain www.tecnalia.com CENTRO RICERCHE FIAT SCPA ("CRF") Italy www.crf.it
The main R&D partners of the project DBT - DOUAISIENNE DE BASSE TENSION SAS ("DBT") France, www.dbt.fr TECHNICAL UNIVERSITY GABROVO ("TUG"), Bulgaria www.tugab.bg Lead partner in the project. Cable charging stations manufacturer, partner with Renault Nissan Alliance Main R&D leader in the project. Part of the tasks: R&D of Inductive Power Transfer systems inverter, IPT coils, compensation & etc.
The main R&D partners of the project Research center of FIAT Group ("CRF"), Italy www.crf.it FUNDACION TECNALIA RESEARCH & INNOVATION ("TECNALIA") Spain www.tecnalia.com Development of communication system between EV and Charging Station. Provides the EV IVECO Daily Hybrid and Li-ion Battery Pack Development of IPT secondary coil positioning system, installed on the EV
Project tasks and goals Development of two charging stations (static and on-route) to be integrated in Douai, France one station for static charging, one station with four coils for test of dynamic charging mode (TU-Gabrovo team) Development of one secondary receiving (Rx) coil to be integrated on the vehicle IVECO Daily System have to be able to control the charging current from the charging station inverter - no secondary side active converter! Optimization of the energy management system. Demonstration of the efficiency and viability of the solution in real-life conditions (TU-Gabrovo team) Study on the exploitation of the solution and the integration in other vehicles and situations. Evaluation of the impact.
2014 2015 WP6: Dissemination and exploitation Work Packages (WP) structure WP1: Specifications WP2: Development of static and on-route fast inductive charging infrastructure: vehicle and stations 2014 2015 WP4: Integration, prototyping and testing WP3: Development of integration solutions: power supply from the grid, energy management, data security WP7: Management 2014 2015 2015 WP5: Demonstration and impact analysis
Simplified Topology of the IPT Charging Station 3x380V / 50Hz 10-30kHz TX RX LF DC DC HF HF DC DC LOAD Converter Control Inductive Power Transfer (IPT) Coils Key feature of the system: Output charging current regulation via primary side inverter! FEEDBACK & LOGIC Wi-Fi FEEDBACK & LOGIC
IPT coils - construction Main structural components of IPT equivalent transformer : 1.Aluminum cover 2.HF Windings flat spiral coils, made from LITZ wire; 3.Ferrite bars
IPT coils electromagnetic field Aluminum cover main function Electromagnetic shield Ferrite bars magnetic shaping, Coupling and Quality factors improvement Combination of both decreasing the levels of electromagnetic dissipation: maximum occupational levels of 27µT @ 3-150kHz, according to ICNIRP Guidelines
IPT coils important parameters The equivalent transformer with large air gap is the main efficiency determining module in the contactless charging station! Representation of parameters, used for IPT coils design and calculation process
IPT coils coupling factor Coupling factor values for different levels of misalignment between Tx and Rx coil
IPT coils quality factor and losses Efficient IPT system is based on: Small air gap and good coupling factor; Appropriate Litz wire cross section and strands dimensions; Converter frequency is equal to frequency with highest quality factor of IPT coils;
IPT coils design results Turns: 13 Wire length: 26m Wire mass: 7.4kg Spacing: No Inductance: 250µH Number of ferrite plates: 144 Mass of ferrite plates : 19kg Overall mass: 39kg Coupling factor: 0.52 Coil losses: 3.3% Turns: 7 Wire length: 14m Wire mass: 4kg Spacing: 8mm Inductance: 60µH Number of ferrite plates: 58 Mass of ferrite plates : 7.7kg Overall mass: 24kg Coupling factor: 0.45 Coil losses: 2% Secondary (Rx) coil 2000Vrms / 10kHZ Secondary (Rx) coil 1200Vrms / 20kHZ
Charging station side Matching and compensation The only possible solution for achieving good efficiency is the use of resonant magnetic coupling between coils. There are many possible compensation topologies serial, parallel, mixed. The choice of compensation depends from output power and application of the system. T-shape with serial compensation (S-S) to П-shape with parallel (P-P) compensation
Charging station side Matching and compensation The design process based on equal inductances L TX = L RX and Serial compensation in both sides of IPT is much simpler for analysis and practical implementation. The impedance is: Impedance of IPT system for operation at resonant frequency ω = ω 0
Charging station side Matching and compensation 2 Primary Matching transformers for every TX Coil, connected in series with transformation ratio 2:1 70A primary current / 210A secondary for each one 2 HF Series connected capacitor banks (2.4uF / 2000V) for compensation of IPT Charging Coil Compensation module (used for two Tx coils)
Charging station side IGBT inverter Advanced Full Bridge Topology One common IGBT module in continuous operation mode Four IGBT modules for the four Charging Coils (Transmitters) Single DC busbar system Common HF potential point (from the common IGBT module)
Charging station side IGBT inverter Modular design simple integration in the charging station housing PCB based inverter busbar Shielded construction for high electromagnetic noise immunity of control boards FPGA control system Air cooled Five gate drivers for each module High pulse power capability up to 45kW @ 1min 5 in 1 inverter module, based on PCB Busbar system
Charging station side modules distribution Modular design Standard housing, manufactured by DBT, France Complex air cooling system High IP protection IP55 with back covers installed 1 Input filter, protection and main contactor 2 IGBT Inverter 3 Matching and Compensation modules Charging station power modules distribution
Electric vehicle side compensation and HF rectifier COMPENSATION AND HF RECTIFICATION MODULE DESIGN GOALS : Small volume and mass 540mm x 400mm x 100mm, 12kg High efficiency - up to 98% High level of protection against dust and moisture Output differential current and voltage measurement Self diagnostic and cooling control
Test results PLC IGBT Inverter Matching and Compensation PLC Secondary compensation and HF rectifier Battery pack Wi-Fi to CAN BUS Wi - Fi Wi-Fi to CAN BUS CAN BUS ANALOG AND DIGITAL SIGNALS HF POWER SIGNALS
Parameter Value Note Nominal Input Power 35kVA According to specifications Peak Input Power 45kVA @ 1min Available for "On route" Efficiency, [%] up to 92% 35kW @ 90mm Nominal Input Voltage 1200V RMS @ 13kHz Continuous mode Nominal Input Current 300A RMS @ 13kHz Continuous mode Transformation ratio 7:7 Primary to secondary Primary (Tx) coil dimensions Secondary (Rx) coil dimensions Switching Frequency, [khz] Test results 700mm x 800mm x 90mm 700mm x 800mm x 60mm 25kHz 13kHz Depends from the compensation, misalignment and type of coils Primary winding mass, [kg] 28kg For the transmitter Secondary winding mass, [kg] 24 kg For the receiver Gap, mm Up to 90mm For appropriate efficiency Horizontal misalignment, mm ΔX=ΔZ= ± 150mm For appropriate efficiency
The end of the project On-route charging station project. By the end of September 2015 the On Route Dynamic charging system will be tested in real urban environment in the city of Douai, France
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