Engineering topics

Eastham, John F.

Publications and source records attributed to Eastham, John F..

3 records

DOE OSTI2024

Design of High-Power Polyphase PCB Coil Systems for Wireless Power Transfer

Printed circuit board (PCB) coils have been proposed prior for implementation as inductive wireless charging coils to minimize size and cost. Utilization of PCBs can allow for a reduced cost, improved manufacturability, and a wide range of geometric customization options. To circumvent material limitations on insulation and thermal performance, parallel paths can be implemented to divide the current per path accordingly. Within this paper, an unconventional high-power PCB coil is designed employing all possible techniques for wiring with axial and radial parallel paths with equivalent transposition to minimize circulating currents. Design studies are simulated in 3D finite element analysis (FEA) to evaluate imbalance between phases with and without transposition. Two experimental prototype coils were fabricated with measurements for self-inductance and mutual inductance between phases. These measurements were validated to be sufficiently consistent with FEA results. Additionally, a method is proposed for a two-step optimization of coupling coefficient and coil losses.

Lewis, Donovin D.↗

DOE OSTI2024

High-Power Polyphase PCB-Type Inductive Coupler for Wireless Electric Vehicle Charging

The cost and manufacturing difficulty of traditionally wound coils for wireless charging of electric vehicles has led to the exploration of alternative manufacturing for scalable deployment at a range of rated powers. A rotating-field polyphase wireless coupler is developed with balanced fully pitched coils which are not possible with conventional Litz wire. The usage of printed circuit board (PCB) technology is proposed for the innovative construction at large dimensions due to reduced cost, increased ease of manufacturability, and potential geometric customization compared to would coils. Design considerations specific to PCBs are detailed for wireless power transfer coils including advantages such as the potential for many turns and transposition with planar interconnections. A design procedure is developed which may be used to investigate the frequency to power to dimension correlation and limits associated with PCB coils. Designs are simulated in 3D electromagnetic finite element analysis (FEA) for the polyphase coil to evaluate the coupling between coils with varying geometric parameters at 100mm and 500mm outer diameters. A discussion is included on methods to increase PCB power ratings through a mixture of layer stacking, connections, and material selection.

Lewis, Donovin D.↗

DOE OSTI2023

Overview of Electrically Conductive and Active Shielding for Wireless Power Transfer with a Polyphase Wireless Electric Vehicle Charging Study

The development and deployment of wireless power transfer (WPT) is increasing across industries including applications in healthcare, sensing and telecommunications, and electric vehicle charging due to its increased mobility and convenience. An important aspect of wireless power transfer is shielding to limit the intensity of electromagnetic fields (EMF) within external regions to protect users and nearby technology. Within this paper, the classifications and recent developments in shielding technologies are reviewed with discussion on potential benefits and drawbacks towards application for wireless charging of electric vehicles (EV). Additionally, a design study is proposed and simulated in 3D FEA for a novel active shield to substantially reduce magnetic field emissions of a high-power, high-frequency rotating-field 3-phase electromagnetic coupler for quickly charging electric vehicles. The active shield, designed to reduce Z-axis emissions, was found to be highly effective, reducing maximum EMF emissions by 83% in aligned static operation and by 50% with lateral misalignment. Active shielding was also found to strongly mitigate the impact of lateral misalignment at each studied partial alignment.

Lewis, Donovin D.↗