Coil Winding Exibition Berlin 2014
Dr.-Ing. Faical Turki

Overview
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History of Contactless Power Supply
Nikola Tesla showing contactless power transfer 1891
Nikola Tesla (1856..1943)
Inventor, Physist, Engineer

Common Application of Contactless Power
Inductive Heating
Heat generation
Inductive Cooking Plate
Quelle: WHD
Inductive charged toothbrush
Battery Charging
Quelle: Duracell
Portable Devices

Principle of Contactless Power Transfer

Industrial Contactless Coil Systems
Profilgeführte
Flach-Pickup
Magnetischgeführte
Flach-Pickup
Mechanischgeführte E-
Pickup
EHB-Profil
U-Pickup
Übetragungsglied Varianten in den Industriellen Anwendungen

Industrial System Components
System overview of a linear contactless power supply application

Industrial System Components

Inductive Power Supply CPS®: Crane Application
Crane 2 x 22 kW equipment in
Virginia/USA

Inductive Power Supply CPS®: AGV-Application
AGV 3 kW SuperCap chargers in Coburg (Kaeser)
1.5 kW AGV-supply with track guiding sensor in Tubos del Mas / Spain

Inductive Power Supply CPS®: Automotive-Production
Automotive application in Neckars Ulm (Audi)
3 kW flat pickup 4 kW E-shaped pickup

Automotive Manufacturing Applications
Volkswagen Dresden (Operating since 2001)
Considerable investigation of safety issues and field emission restrictions
Primary coils all over the active area working at
55 … 80A, 20 kHz
Secondary Pickup as multicoil for position tolerance

Inductive Power Supply CPS®: Transfer Car
1.5 kW equipment for metal industries in Alicante (Alcoa)

Inductive Power Supply CPS®: EMS-Application
Electric Monorail System with 1.5 kW U-shaped pickup in Ditzingen (Siemens)

Inductive Power Supply CPS®: Sorter-Application
150 W-Pickup in Mayoral (Sandvik/Cinetic)

Inductive Power Supply CPS®: Clean Room Application
2 x 22kW E-shaped pickups for TFT-Display production /
Clean-room
(Sharp/Japan)

Inductive Power Supply CPS®: Elevator Application
Elevator application and 5kW flat pickup (Cinema in Moskau)

Contactless Power Supply of the Transrapid TR09
First Prototype for
250kW Power Supply
Transrapid Test Track
TVE Lathen with 2x250kW
Rated Power

Contactless Power Supply for Trams
Pilot track in
Augsburg:
Dynamic contctless charging (while driving)
Quelle: Bombardier Transportation
Up to 160kW per
Segment, switched on at vehicle detection

Vahle 3kW Charging Systems for Electric Vehicles
Location at the bottom of the car Location under the number plate

VAHLE Project – Wireless charging via number plate
– E-car: Karabag (Fiat) 500e.
– Inductive charging (3 kW).
– 125V battery voltage.
– Conductive charging (3 kW) also possible.

Concept of Inductive Battery Charger for Electric Vehicles
| simple charging process without interaction of the driver
| no plugging, automatic start of battery charging
| no cables to handle inside or outside the car
| robust against vandalism and sabotage
| no contact required and no exposed electric wires
| feedback signal for positioning
| bidirectional data transfer
| barrier-free and can be driven over
| optionally integrated underneath the floor
| foreign object detection in the air gap
| low volume and weight on the vehicle
| high efficiency
20.06.14

System Overview of inductive chargers

Inductive charging systems for electric and hybrid vehicles
Coil Variant 1
Unipolar rectangular
 Widespread
 Large rotational angle tolerance
 Magnetic flux is concentrated centrally with distributed magnetic yoke on all outside edges

Inductive charging systems for electric and hybrid vehicles
Coil Variant 2
Bipolar “Solenoid”
 Bipolar, symmetrical
 Lower rotational angle tolerance
 Flux flow in the outer region of the coil requires shielding on vehicle underbody

Inductive charging systems for electric and hybrid vehicles
Coil Variant 3
Bipolar “DD”  A bipolar field by means of two planar coils in the primary circuit with different flux directions
 Lower rotational angle tolerance
 No turns in the outer area below the primary coil, no shielding needed

Foreign Object Heating
Conservative Magnetics Design
• Pin = 3,6 kW
• η ≥ 90%
• f = 140 kHz ± 10 kHz
• 1-phase
• Circular
• No dangerous metal heating
• No Sensors

Low Field Primary Coil
Prototype of the top case with milled nuts for the copper wires
Seite 34
Präsentationstitel
Simulated flux density on the top of the coil

Low Field Primary Coil
Flux density on the primary pad

Circular Coil Pickup Sizes for 3,6 kW
800 mm m = 15 kg
Pnom = 3 kW fnom = 140 kHz
No FOD required *
External compensation and rectifier:
V = 5 dm³ m = 4 kg
* FOD=Foreign Object Detection
800 mm
15 mm
300 mm
300 mm
20 mm m = 5 kg
Pnom = 3 kW fnom = 140 kHz
FOD mandatory *
External compensation and rectifier:
V = 3,3 dm³ m = 2 kg

Cooperation Hella / Vahle: Prototype

Inductive charging systems for electric and hybrid vehicles
Prototype components
Cu – Windings : generate Field
Ferrite : Field guide
Aluminium : Shielding
Bottom Plate
 Primary circuit (L,C)
 Can be driven over
 Sensors for additional function
 Integrated power electronics [Future]
Pick-up
 Secondary circuit (Rectifier)
 Small, lightweight
 Sensors for power transmission and additional functions

Inductive charging systems for electric and hybrid vehicles
Efficiency
Battery Charging Efficiency DCout/ACin
η>90%
 During constant current charging
 Until about 90% SOC
Efficiency DCout / ACin of inductive charging is only slightly lower than that of conductive charging

System Overview of bidirectional inductive chargers

Bidirectional Power Electronics

Efficiency measurements in both feeding directions

Inductive charging systems for electric and hybrid vehicles
Foreign body monitoring
VDE-AR-E 2122-4-2
1.
Functions - and the transition region
1 2 a) Heating @40°C T<80°C (metallic Obj)
T<90°C (non-metallic Obj) b) Inflammation is not permitted
2.
Transition - and public area 3 4
Personal protection as ICNIRP guideline, that is, much safer than German 26 BlmSchV
 Compact design = High flux density
 Eddy currents in metallic objects leads to heat / inflammation; required detection (FOD = Foreign
Objects Detection).
 Compliance permitted for persons flux density (6.25
μT) in the outdoor area is safe; under the vehicle detection of organisms (LOD)
 LOD / FPS: interruption of energy transfer
Twenty-sixth regulation
Execution of the Federal Pollution Control Act
(Decree on electromagnetic fields 26 BlmSchV) (27µT)

• Thin plastic sheet on top of primary coil, (secondary coil optional)
• First prototype detects objects on surface
• 50 cent coin
• cigarette pack
• gum wrapper
• 330 ml beverage can
• Possible increase of detection distance up to 20 mm for larger objects by optimizing internal structure

Magnetic field simulation analysis:
Top view Side view
Flux density will be lower than 6.3 µT (colored in dark red) at the borderline of the vehicle

Test with CW Radar Sensor
Integration approach:

Inductive charging systems for electric and hybrid vehicles
Positioning assistance
Support for the driver for optimum X and Y charging position
 when approaching, 5-30m
 At close range, ~ 1m
 at end position
With increasing accuracy
Communication
 Directional and distance information in the cluster or at the wallbox
 Virtual top view with guidance
 Perspective automation like parking assist
Approaches
 Optical / camera systems - Visibility
 Radio-based systems
 RFID
 Power Transformers

Inductive charging systems for electric and hybrid vehicles
Radio system compatibility - keyless access and drive authorization
 Data transmission from the vehicle to the ID transmitter, f = 125kHz (25kHz, 132kHz ...)
 Disturbance of the LF data reception by strong magnetic field of charging vehicle hinders the charging vehicle and its neighbors
H in dBµA/m
ID-Transmitter

Inductive charging systems for electric and hybrid vehicles
Keyless entry LF compatibility – 70dbµA/m ISO
Kessy LF Font View Side View
Top View
The 70dBμA/m surface with unipolar rectangular WPT encloses the keyless entry 70dBμA/m surface. In this area no Keyless Entry LF communication is possible
WPT 140kHz

Inductive charging systems for electric and hybrid vehicles
Keyless entry LF compatibility – 100dbµA/m ISO
Kessy LF Front View Side View
Top View
Die 100dBµA/m WPT ISO encloses the Keyless Entry
100dBµA/m ISO not completely – Keyless Entry LF
Communication is possible, depending on location, frequency, receiver and, if necessary, further measures.
WPT 140kHz

Inductive charging systems for electric and hybrid vehicles
Summary and outlook
 Precondition for the widespread implementation of electric mobility
 Based on known technologies in new designs and combinations challenging, but achievable system
 Allows comfortable and convenient charging
 Compatibility with vehicle radio systems and other radio systems required
 Interoperability between systems and sub-systems of various vehicle and system manufacturers will become necessary in future
 Dynamic chargers in concept phase

Representations in 52 countries worldwide

Dr.-Ing. Faical Turki
Paul Vahle GmbH und Co. KG, Westicker Str. 52, 59174 Kamen faical.turki@vahle.de
Tel.: 02307 / 704 271