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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
DOE OSTI2019

Sensitivity Analysis of an LCC-LCC Compensated 20-kW Bidirectional Wireless Charging System for Medium-Duty Vehicles

In this paper, sensitivity analysis of an LCC-LCC compensated bidirectional wireless charging system is presented. In a wireless charging system for electric vehicle applications, the effective load impedance varies significantly with the state-of-charge (SOC)of the battery. Due to the change in system parameters, resonant frequency, and transferred power, the efficiency of the system varies significantly. Sensitivity analysis of the system characteristics reveals the optimal operating region and required control strategy to operate within that region. Sensitivity analysis is even more important for a bidirectional system with mismatched input and output voltage levels. In this paper, the sensitivity of a bidirectional 20 kW wireless charging system is investigated analytically and the results are validated experimentally. The experimental results for a geometrically matched Double-D (DD) coil-based LCC-LCC tuned bidirectional WCS with asymmetric voltage levels show that the voltage gains and input impedance of the system are highly sensitive near the resonant frequency.

Mostak, Mostak Mohammad↗
DOE OSTI2019

Wireless charging and shared autonomous battery electric vehicles (W+SABEV): synergies that accelerate sustainable mobility and greenhouse gas emission reduction

Emerging technologies play important roles in shaping future mobility systems and impacting sustainability performance of the transportation sector in major economies, such as the United States of America (USA) and China. This study applies a life cycle framework to demonstrate and evaluate the synergies of the following four emerging transportation system technologies both qualitatively and quantitatively: (1) wireless charging; (2) shared mobility services; (3) autonomous driving; and (4) battery electric vehicles (BEV). The new concept of a wireless charging and shared autonomous battery electric vehicle (W+SABEV) system is introduced and modeled. First, an analytical framework is presented to assess the pros and cons of the W+SABEV system vs. a conventional plug-in charging BEV system, adhering to the principles of sustainable mobility and highlighting the impacts and dynamics of the disruptive technologies on the key parameters that define sustainable mobility. Second, a quantitative analysis presents the synergies of the four technologies by modeling a W+SABEV system and demonstrates that the combination of the four technologies can shorten the payback time of greenhouse gas (GHG) emission burdens for infrastructure and vehicles. Finally, compared to a plug-in charging BEV system, a W+SABEV system pays back the additional GHG emission burdens of wireless charging infrastructure deployment within 5 years if the wireless charging utility factor (ratio of en route charging time vs. trip time) is above 19%.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2026

Optimal Litz Wire Design for High-Power Wireless Charging System

In this study, an optimized Litz wire and polyphase coil winding design is proposed for high-power wireless charging systems operating at 85 kHz frequency. Litz wire in a wireless charging system contributes to more than half of the losses of the system, making it a critical design component. Here, the Litz wire is optimized through Finite Element Analysis (FEA) considering electrical and mechanical design aspects and the design was validated through experimental tests on different Litz wires with various strand-diameters, twisting ratio, and number of strands. The proposed optimal Litz wire maximizes the system efficiency considering the tradeoff between coil resistance and mutual inductance. The optimal Litz wire shows that Litz wire constructed with the 63µm strands significantly outperform the traditionally used Litz wire with 100µm strand diameter. Additionally, the coil with optimal Litz wire design shows 60% reduction in the copper volume for the same loss, and at the same time increase the coil-to-coil efficiency by more than 2% by increasing the mutual inductance and reducing coil current. The optimized Litz wire was implemented in a 22-kW wireless charging system achieving 94.7% efficiency.

Aydin, Emrullah [ORNL]↗
DOE OSTI2020

Real-Time Implementation of Smart Wireless Charging of On-Demand Shuttle Service for Demand Charge Mitigation

This paper presents a smart charge management strategy for an on-demand electric shuttle operating at the National Renewable Energy Laboratory (NREL) campus and supported by an inductive charger at the vehicle's waiting spot. A new control algorithm has been proposed for mitigating the demand charges incurred from the wireless charger. It monitors the shuttle, wireless charger, renewable energy generation, and other loads and regulates charging behavior for demand charge mitigation. Within the control algorithm, an energy prediction is made to estimate the mobility needs of the vehicle and maintain uninterrupted service during operation while still minimizing peak demand. The proposed controller is designed and optimized using a Simulink model for the entire system. It is then implemented and tested in real time at the NREL campus using online cloud services. Two vehicle-use cases' charge-sustaining and charge-depletion operation' are tested under different campus power profiles and drive cycles to assess the controller's performance. In this work, the proposed controller showed a robust performance under different driving scenarios, with high correlation between simulation and experimental data. The results show that proper demand response can be achieved, with an average of 94% reduction of charging loads during peak demand events.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2023

Modular Power Electronics Approach for High Power Dynamic Wireless Charging System

Dynamic wireless power transfer (DWPT) can provide energy to EVs in motion and extend the drive range. Upscaling the charging power to 200 kW (High Power DWPT) reduces the percentage of electrified roadway required, and the solution becomes cost-effective. To smooth the power at the battery and grid, a secondary regulation stage must be added. The DWPT system therefore relies on power electronics to interface with the coils and regulate the power flow. Designing this high power system using wide bandgap devices makes ensuring high efficiency, small size, and reliable operation very challenging, and significant engineering effort is required to build such complicated systems for large-scale installation and deployment. Here, this paper describes a modular design approach for the power electronics to achieve the 200 kW wireless power transfer. As described, the SiC power electronics building block is designed, simulated, and characterized. The approach is validated in the DWPT system to build the inverter, the rectifier, and the DC/DC converter, which demonstrated high performance and reliable operation with 188 kW power.

42 ENGINEERING↗
DOE OSTI2021

Modular Design of Receiver Side Power Electronics for 200 kW High Power Dynamic Wireless Charging System

Dynamic wireless power transfer (DWPT) can provide energy to EVs in motion and extend the drive range. By upscaling the charging power to 200 kW (High Power DWPT), the percentage of electrified roadway reduces and the solution becomes cost-effective. However, coil coupling-coefficient variation during vehicle movement fluctuates the transferred power which is unfavorable for vehicle battery. Secondary regulation design can smooth the power but the converter design becomes very challenging due to requirement in high power, high efficiency, fast control, as well as high power density since the unit will be onboard. This paper provides the modular design approach of a 200 kW secondary side unit to achieve high performance and scalability. The DC/DC converter using SiC devices demonstrated 98.3% efficiency.

Xue, Lincoln↗
DOE OSTI2022

Design and Analysis of a 200 kW Dynamic Wireless Charging System for Electric Vehicles

Dynamic wireless charging of electric vehicles can significantly alleviate or eliminate range anxiety while reducing the required on-board battery capacity. To achieve an electric vehicle charging balance with minimal infrastructure costs, power transfer levels around 200 kW are required. In this paper, a system architecture with a modularized power electronics and optimized power transfer couplers was adopted to enable efficient power transfer. A DC/DC converter was used for secondary-side charging control of the battery. The system performance was validated in an experimental setup at 120 kW with 91.31% efficiency from the DC input on the primary side to the vehicle battery.

Xue, Lincoln↗
DOE OSTI2016

Oak Ridge National Laboratory Wireless Charging of Electric Vehicles - CRADA Report

Wireless power transfer (WPT) is a paradigm shift in electric-vehicle (EV) charging that offers the consumer an autonomous, safe, and convenient option to conductive charging and its attendant need for cables. With WPT, charging process can be fully automated due to the vehicle and grid side radio communication systems, and is non-contacting; therefore issues with leakage currents, ground faults, and touch potentials do not exist. It also eliminates the need for touching the heavy, bulky, dirty cables and plugs. It eliminates the fear of forgetting to plug-in and running out of charge the following day and eliminates the tripping hazards in public parking lots and in highly populated areas such as shopping malls, recreational areas, parking buildings, etc. Furthermore, the high-frequency magnetic fields employed in power transfer across a large air gap are focused and shielded, so that fringe fields (i.e., magnetic leakage/stray fields) attenuate rapidly over a transition region to levels well below limits set by international standards for the public zone (which starts at the perimeter of the vehicle and includes the passenger cabin). Oak Ridge National Laboratory s approach to WPT charging places strong emphasis on radio communications in the power regulation feedback channel augmented with software control algorithms. The over-arching goal for WPT is minimization of vehicle on-board complexity by keeping the secondary side content confined to coil tuning, rectification, filtering, and interfacing to the regenerative energy-storage system (RESS). This report summarizes the CRADA work between the Oak Ridge National Laboratory and the Toyota Research Institute of North America, Toyota Motor Engineering and Manufacturing North America (TEMA) on the wireless charging of electric vehicles which was funded by Department of Energy under DE-FOA-000667. In this project, ORNL is the lead agency and Toyota TEMA is one of the major partners. Over the course of the project, ORNL and Toyota TEMA worked closely on the vehicle integration plans, compatibility, and the interoperability of the wireless charging technology developed by ORNL for the vehicles manufactured by Toyota. These vehicles include a Toyota Prius Plug-in Hybrid electric vehicle, a Scion iQ electric vehicle, and two Toyota RAV4 electric vehicles. The research include not only the hardware integration but also the controls and communication systems development to control and automate the charging process for these vehicles by utilizing a feedback channel from vehicle to the stationary unit for power regulation.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2016

An Optimal Deployment of Wireless Charging Lane for Electric Vehicles on Highway Corridors

We propose an integrated modeling framework to optimally locate wireless charging facilities along a highway corridor to provide sufficient in-motion charging. The integrated model consists of a master, Infrastructure Planning Model that determines best locations with integrated two sub-models that explicitly capture energy consumption and charging and the interactions between electric vehicle and wireless charging technologies, geometrics of highway corridors, speed, and auxiliary system. The model is implemented in an illustrative case study of a highway corridor of Interstate 5 in Oregon. We found that the cost of establishing the charging lane is sensitive and increases with the speed to achieve. Through sensitivity analyses, we gain better understanding on the extent of impacts of geometric characteristics of highways and battery capacity on the charging lane design.

Huang, Yongxi↗
DOE OSTI2020

Concept Design of Active Shielding for Dynamic Wireless Charging of Light-duty EV

Dynamic wireless charging of electric vehicles is a flexible and state of the art charging technology with the potential capability of enabling fully automated in-motion charging. With charging power increasing to more than 100 kW for light duty vehicles, electromagnetic field (EMF) emission becomes a critical challenge. Due to the high costs of ferrite materials, this paper proposes an active shielding solution with multiple canceling coils installed on the ground side to supplement ferrite passive shielding to ensure electromagnetic safety. Two canceling coils are designed on two sides of the ground side coil. The canceling coils are small in size and 180 degree opposite in phase to the ground coil. Simulation and modeling shows that the canceling coils can reduce EMF emission from 37.2 µT to 18.2 µT at 0.8 m during 100 kW operation with only 2.5% of ground side current flowing in the canceling coils. These results have been preliminarily verified by inductance measurements and magnetic field measurement at 1.1 m distance without canceling coils. By further increasing the canceling coils’ currents to 4%, EMF emission can also be mitigated at 200 kW, although the canceling coils’ shape, position, and phase angle can be further optimized to improve the three-dimensional field distribution.

25 ENERGY STORAGE↗
DOE OSTI2016

A High-Power Wireless Charging System Development and Integration for a Toyota RAV4 Electric Vehicle

Several wireless charging methods are underdevelopment or available as an aftermarket option in the light-duty automotive market. However, there are not many studies detailing the vehicle integrations, particularly a complete vehicle integration with higher power levels. This paper presents the development, implementation, and vehicle integration of a high-power (>10 kW) wireless power transfer (WPT)-based electric vehicle (EV) charging system for a Toyota RAV4 vehicle. The power stages of the system are introduced with the design specifications and control systems including the active front-end rectifier with power factor correction (PFC), high frequency power inverter, high frequency isolation transformer, coupling coils, vehicle side full-bridge rectifier and filter, and the vehicle battery. The operating principles of the control, communications, and protection systems are also presented in addition to the alignment and the driver interface system. The physical limitations of the system are also defined that would prevent the system operating at higher levels. The experiments are carried out using the integrated vehicle and the results obtained to demonstrate the system performance including the stage-by-stage efficiencies with matched and interoperable primary and secondary coils.

plug-in electric vehicle charger↗
DOE OSTI2020

Shield Design for 50 kW Three-Phase Wireless Charging System

In this paper, magnetic field emissions (MFE) from a 50 kW bipolar coil-based three-phase wireless charging system (WCS) is investigated. Then, a shield design is proposed to suppress the MFE below the safety limit identified by the International Commission of Non-Ionized Radiation Protection (ICNIRP) guidelines. Bipolar coil-based three-phase (3φ) WCSs provide extremely high power-density; therefore, the 3φ WCSs are highly promising for high-power fast-wireless-charging of the electric vehicles. For the high-power EV application, it is a critical challenge to design a shield to suppress the MFE below the safety limit. The traditional aluminum shield is found ineffective for the bipolar 3φ-WCS. The proposed shield is designed with high-permeability magnetic material, i.e. ferrite, nanocrystalline material, etc. The proposed shield is simulated in finite element analysis (FEA) and the FEA results show that the proposed magnetic shield effectively suppresses the magnetic field emission below the ICNIRP limit. The generalized design of the proposed shield can be used for even higher power bipolar coil based WCSs.

Mohammad, Mostak↗
DOE OSTI2021

Three-Phase LCC-LCC Compensated 50-kW Wireless Charging System with Non-Zero Interphase Coupling

In this paper, an LCC-LCC compensated 50 kW 3phase (3φ) wireless charging system with nonzero interphase mutual inductance is demonstrated. The 3φ-LCC compensation is designed considering a nonzero mutual-inductance among the phase-coils to meet resonance criteria, balance voltages and currents of the resonant tank components, achieve desired voltage gain, and ensure the zero-voltage switching (ZVS) operation. An experimental prototype of the 3φ-LCC-LCC compensation circuit is built for a 50 kW bipolar coil-based 3φ wireless charging system. The prototype system was tested at rated 50 kW power for evaluating the efficiency, ZVS operation, electric and magnetic field emissions, and thermal characteristics. The experimental results show 94.3% dc-to-dc efficiency and only 4.4 μT rms magnetic field emission at the rated 50 kW output power.

Mohammad, Mostak↗
DOE OSTI2022

Magnetic Shield Design for the Double-D Coil-Based Wireless Charging System

In this work, magnetic field emission (MFE) of the high-power double-D (DD) coil-based wireless charging system is investigated and a shielding technique is proposed. The MFE pattern produced by the DD coils is significantly different from the MFE of the unipolar (e.g., circular, square, or rectangular) coils, and the traditional aluminum shield does not suppress the MFE from the DD coils. This study shows that a conventional aluminum shield increases the MFE, and a magnetic shield effectively suppresses the MFE of the DD coils. Therefore, a magnetic shield consisting of high-permeability magnetic material, such as ferrites, nanocrystalline, etc., is proposed for the DD pads. The shielding effectiveness of the proposed shield is evaluated through finite element analysis and verified through experiments. An 11 kW DD coil-based wireless charging system was used to test the proposed shielding technique. The experimental results show that a traditional aluminum shield increased the MFE by 29.8%, and the proposed magnetic shield suppressed the MFE by 50.5%.

42 ENGINEERING↗
DOE OSTI2019

Design of an EMF Suppressing Magnetic Shield for a 100-kW DD-Coil Wireless Charging System for Electric Vehicles

This study investigates the electromagnetic field (EMF) emissions of a 100-kW Double-D (DD) wireless charging system (WCS). A shielding technique is proposed to suppress the magnetic field emissions below the limits set by the International Commission on Non-Ionizing Radiation Protection (ICNIRP). The leakage pattern produced by the DD coil is different than unipolar (circular, rectangular, etc.) pads and traditional eddy current based aluminum shields are not effective at suppressing this leakage field. Therefore, a methodically designed magnetic shield could be more effective. This study proposes a shielding technique for DD coils using a combination of aluminum shielding and a low reluctance magnetic shield to suppress the magnetic field emissions. The shielding effectiveness is evaluated through finite element analysis (FEA) models and tested experimentally. The effectiveness of the proposed magnetic shielding and the limits of the conventional aluminum shielding are studied. A prototype 11-kW DD coil wireless charging system is used to experimentally validate the proposed shielding technique. The experimental results show that the aluminum shield increases the emissions of DD coils by 25% and the proposed magnetic shield can be employed to suppress the emission by 60%.

Mohammad, Mostak↗
DOE OSTI2018

Comparison of 22 kHz and 85 kHz 50 kW Wireless Charging System Using Si and SiC Switches for Electric Vehicle

Fast charging in transportation application requires high-power (>50 kW) operation. The overall size of wireless charging systems (WCS) must increase to meet the high-power requirement. As a result, high power systems produce more electromagnetic field (EMF) emissions. Although higher operating frequencies (85 kHz) reduce the size of inductors and capacitors, system losses tend to increase. High-power systems are traditionally investigated for 10 kHz to 22 kHz operation to reduce the switching loss in the converter, and conductive and magnetic losses in the power pad. The use of SiC MOSFETs reduces conduction and switching losses in the converter even at higher frequencies. In this paper, a comprehensive loss comparison of 50 kW wireless charging system is conducted for 85 kHz and 22 kHz operation of Si MOSFET and SiC MOSFET converters. Detailed performance indexes are compared analytically as a function of frequency and verified using FEA and PLECS. This comprehensive system level study shows that magnetic losses can be reduced significantly, and that EMF emission can be reduced by 50% by moving from 22 kHz to 85 kHz. Moreover, the system requires 50% less copper and allows a significant reduction in the size of the primary and secondary filter capacitor at 85 kHz. The results show that the system efficiency at 85 kHz can be increased by 21% compared to 22 kHz operation by using a SiC MOSFET converter.

Shahidul haque, Moinul↗
DOE OSTI2022

Sizing Considerations for EV Dynamic Wireless Charging Systems with Integrated Energy Storage

Roadways with dynamic wireless charging systems (DWCS) enable charge-sustaining in-motion EV charging, which can reduce charging idle time while increasing range capabilities. Spatially distributed transmitter coils are controlled in response to traffic load that varies significantly minute to minute with high power levels, very short charging time, and low system utilization like wind turbine power. Traffic load estimation and localized analysis may guide effective sizing and topology adoption for feasible and scalable DWCS deployment. DWCS traffic load approximation is reviewed with measured Automated Traffic Recorder (ATR) data and statistical distributions being used to create a synthetic load analyzed using proposed metrics quantifying system utilization over time. Lumped coil section segmentation is compared between second-based distance and spatial density analysis methods, offering 17-27% greater system utilization. A peak load shifting method is proposed for traffic redirection across two tracks with optional BESS integration increasing system utilization by 50-60% depending on time-based and power reserve-based sizing and control.

Lewis, Donovin D.↗