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Costinett, Daniel

Publications and source records attributed to Costinett, Daniel.

7 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Fourier Analysis and Design of a Shielded 120kW Inductive Wireless System

High-power inductive wireless power transfer (WPT) systems for EVs are designed to meet specifications such as stray field, power level, efficiency, misalignment tolerance, and ground clearance. These metrics are all heavily influenced by the coil geometry. Herein this paper proposes a coil design method based on the Fourier Analysis Method (FAM) which is an analytical method for directly designing coil geometries to meet stray field and power level requirements through an optimization of Fourier basis function coefficients. In this work, two 120 kW WPT proof-of-concept demonstrators with low stray field and high efficiency are built from FAM optimization results to validate the models and show the impact of the FAM design process. Experimental validation of the Gen. 2 demonstrator at 120 kW output power resulted in a measured DC/DC efficiency of 97.2% at alignment with a 125 mm airgap. At the 120 kW test point, the stray fields 80 cm away from the center of the airgap between the coil assemblies were 3.4 µT(rms) on the X-axis and 3.5 µT(rms) on the Y-axis, much lower than the 27 µT(rms) ICNIRP limit.

42 ENGINEERING↗
DOE OSTI2024

Fourier Analysis and Loss Modeling for Inductive Wireless Electric Vehicle Charging with Reduced Stray Field

With the growth of electric vehicle (EV) popularity, different charging options to increase user convenience and reduce charging times are being considered and researched. Among these, inductive wireless power transfer (WPT) systems for EVs are being designed to meet specifications such as stray field, power level, efficiency, misalignment tolerance, and ground clearance, which are all heavily influenced by the coil geometry. The proposed Fourier Analysis Method (FAM) is an analytical method to directly design coil geometries to meet stray field and power level requirements through an optimization of Fourier basis function coefficients. The outputs of the optimization are complex, planar coil geometries that meet the power level and stray field constraints with minimized loss factors. Contours of these potentials determine the coil conductor paths and loss models predict the system efficiency and performance over misalignment. The Fourier representation of the geometry is used to conveniently calculate the coupling over misalignment, external proximity effect loss, and ferrite loss. A 6.6 kW prototype WPT system with low stray field and high efficiency is built from the optimization results to validate the models and showcase the usefulness of the FAM design approach.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2023

Encapsulation Residual Stress and Ferrite Loss in Inductive Coil Assemblies

As inductive wireless charging reaches higher power levels, thermal management and mechanical durability become more critical. To address these concerns, past works have demonstrated the benefit of encapsulating coil assemblies in thermally conductive materials. However, due to the sensitivity of the MnZn ferrites commonly used in coil assemblies to mechanical stress, care must be taken to avoid creating large stresses in the ferrite that cause higher hysteresis loss. The stress formation in the encapsulant curing process is overviewed and modeled and an experiment is performed to demonstrate the effect in a small-scale coil assembly. Finally, the effect is shown in the reduced coil-coil efficiency of a first generation high power inductive power transfer prototype using a stiff epoxy compared to better performance in a second prototype using a softer thermally-conductive silicone encapsulant.

Foote, Andrew↗
DOE OSTI2022

Multilevel Switched-Capacitor AC–DC Step-Down Rectifier for Wireless Charging With Reduced Conduction Loss and Harmonic Content

In this paper, a wireless charging architecture employing a multilevel switched-capacitor (MSC) AC-DC rectifier is investigated. The proposed MSC rectifier features a multilevel design which is scalable to accommodate different power ratings and load ranges. The topology showcases advantages for wireless power transfer (WPT) systems in terms of compactness, efficiency, impedance tunability, and harmonic attenuation. The single-stage active topology is capable of varying its low-distortion staircase input voltage to tune the wireless power transfer system for high system-wide efficiency. A 7-level, 20 W prototype is used to verify the WPT loading and loss analysis. The prototype operates at 150 kHz with up to 3:1 step-down conversion ratio to an output voltage of 5.0 V. The experimental peak DC-to-DC efficiency is 93.8% and the rectifier peak efficiency is 98.3%. As a result. the rectifier demonstrates low waveform distortion and high efficiency across many WPT loading conditions, solidifying its place as a strong candidate for wireless power applications.

42 ENGINEERING↗
DOE OSTI2020

Fourier Analysis Method for Wireless Power Transfer Coil Design

Wireless power transfer (WPT) systems for Electric Vehicles (EVs) are designed to meet specifications such as stray field, power transfer, efficiency, and ground clearance. Typical design approaches include iterative analysis of predetermined coil geometries to identify candidates that meet these constraints. This work instead directly generates WPT coil shapes and magnetic fields to meet specifications and constraints through the optimization of Fourier basis function coefficients. The proposed Fourier Analysis Method (FAM) applies to arbitrary planar coil geometries and does not rely on iterative finite-element analysis (FEA) simulations. This flexibility allows for rapid design evaluation across a larger range of coil geometries and design specifications. A prototype coil is built to compare FAM outputs to experimental measurements and FEA simulations. The FAM is then used to illustrate the tradeoff of coil current and stray field for a given power level showing that the method is capable of generating optimized coil shapes to meet arbitrary field constraints.

Foote, Andrew↗