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DOE OSTI2022

A 20-kW DC Oak Ridge Converter with Integrated AC & DC Sources for Grid Services and Energy Storage Systems

This paper proposes a wireless power transfer (WPT) platform with integrated energy conversion that has the capability for 1) recharging the energy storage systems (ESSs) from the grid systems, including renewable energy sources such as wind, solar, etc., 2) off grid systems recharging the ESSs from dc grid systems, 3) grid recharging of electric vehicles (EVs), and 4) off grid recharging of EVs from ESSs. The unique aspect of the method is the use of multi-interface power electronic converter for the grid and ESSs and EVs that can support a range of applications with ac / dc and dc / dc energy conversion ability in a single converter system. The key enabling technology to achieve these functionalities is Oak Ridge Converter (ORC) with polyphase coupler coil system both developed at ORNL. This new technology enables higher power density WPT systems while allowing the coils to interface from ac grid at 60 Hz frequency or dc source directly merging with 85 kHz operating frequency of switching component. The experimental results of the proposed system are presented for 20 kW output power with the system overall efficiency around 95.4% from dc source and 93% overall efficiency from ac grid achieving 9-10% current total harmonic distortion (THD) and 0.98-0.99 power factor (PF).

Asa, Erdem↗

DOE OSTI2024

Thermal Analysis of a 100 kW Polyphase Wireless Power Transfer System

Charging Electric Vehicles (EVs) fast and safely has a crucial role in the future of the EV technology. High-power Wireless Power Transfer (WPT) helps to significantly decrease the charging time. However, when the power transfer levels increase, thermal management becomes a significant challenge. The thermal design of the WPT systems needs more consideration in the design and implementation steps. This paper presents a thermal analysis of a 100 kW high-power WPT system. The thermal performance of the proposed design was evaluated at different power levels by considering the magnetic design and loss analysis. Finite Element Analysis (FEA) of the proposed design was performed and the thermal images of the implemented system were taken to prove the simulation results. The results show that, a liquid cooling design is needed for a high-power WPT systems for the long-time continuous operations of the charging pads.

Aydin, Emrullah↗

DOE OSTI2025

Circuit Modeling, Simulation, and Experimental Validation of a 100-kW Polyphase Wireless Power Transfer System for EV Applications

Polyphase wireless power transfer (WPT) systems can achieve much higher surface power densities (kW/m2) and specific power levels (kW/kg) compared to the conventional circular single phase WPT systems. Therefore, polyphase WPT systems can reduce the size, weight, volume, and cost of the WPT systems and can simplify the electric vehicle integration with less demand for space. This study presents the high-performance and compact 100-kW WPT development using polyphase electromagnetic coupling coils with rotating magnetic fields.

Onar, Omer [ORNL] (ORCID:0000000292028857)↗

DOE OSTI2020

Electromagnetic Shielding Design for 200 kW Stationary Wireless Charging of Light-Duty EV

Wireless power transfer (WPT) is a developing technology with the advantage of convenience and flexible charging. SAE recommended practice J2954 defines typical size and geometry with aluminum or ferrite plate shielding to limit leakage electromagnetic (EM) fields for WPT with power levels lower than 22 kVA from the input side. However, as the WPT power goes up to 100- or 200-kW level, EM safety surrounding the WPT becomes a critical concern. To address this oncoming safety challenge, a novel ferrite shielding design is proposed in this paper. Different misalignment scenarios in accordance with definitions in SAE J2954 are also taken into consideration to ensure EM safety under various operation scenarios. Simulation results, which are preliminarily verified by magnetic field measurements at 1.1 m from the center of the vehicle side coil under 100 kW operation, indicate that the magnetic field leakage can be maintained below the limits defined in SAE J2954 for 200 kW operation. A 3.3 kW scale-down test was also carried out and compared to parallel scale-down simulations. 26.8% field emission reduction is observed from the scale-down test, which supports the effectiveness of the proposed shielding design.

Zhang, Bo↗

DOE OSTI2020

Control of Output Power in Primary Side LCC and Secondary Series Tuned Wireless Power Transfer System without Secondary Side Sensors

The output power of a wireless power transfer (WPT) system varies with load and coupling factor of the inductively coupled coils. This paper presents a method to control the output power of primary side LCC and secondary side series tuned WPT system using information of primary side variables. In this approach, a secondary side control system or secondary side sensors are not needed. Detailed mathematical derivations are given to identify and justify the suitable primary side variable that accomplishes the desired purpose without the need of any secondary side communications. Simulation results presented validate the proposed scheme.

Mukherjee, Subho↗

DOE OSTI2025

Output Current Estimation and Control in Primary Side LCC Secondary Side Series Compensated Wireless Power Transfer System without Secondary Side Sensors

The estimation (and control) of the output variables is often challenging for wireless power transfer (WPT) systems. This paper presents a secondary side sensor-less closed loop estimation technique to estimate the output current in a primary side LCC and secondary side series compensated WPT system. Using information of primary side variables, the proposed estimation can estimate the output current over a wide range of load current variations. Results are presented to verify the efficacy of the proposed estimation.

Mukherjee, Subho [ORNL] (ORCID:0009000672297925)↗

DOE OSTI2020

Methods to Synchronize and Control the Secondary Side Active Rectifier in Wireless Power Transfer Systems

This paper presents practical analog circuit-based methods to synchronize the secondary side active bridge of different wireless power transfer (WPT) systems with their primary side. The synchronization is necessary for proper operation of any WPT system with an active bridge on the secondary. The proposed schemes use only secondary side signals without the need of any information from the primary side. Simulation results presented validate the proposed schemes.

Mukherjee, Subho↗

DOE OSTI2023

Efficiency and Output Power Sensitivity to Control Parameter Variations in an LCC-Series Wireless Power Transfer System

In wireless power transfer (WPT) systems, output power (Pout) can be controlled through input parameters such as, input voltage (Vin) , duty cycle (d) , and switching frequency (fsw) . The impact of these control parameters on the overall system efficiency has not been explored in previous studies. This paper focuses on the efficiency (η) and Pout sensitivity to these control parameter variations in an LCC-Series tuned WPT system. There are multiple combinations of Vin, d , and fsw that can achieve a specified target Pout . However, it is important to determine the optimal combination of these control variables that will yield the maximum η for a target Pout . A MATLAB/Simulink model is built to calculate and measure η and Pout . In order to achieve this result, several simulations are run where Vin,d , and fsw are swept across a wide range to cover all possible combinations. MATLAB's Sensitivity Analysis toolbox is used to evaluate how the parameters influence the model's output. Finally, an experimental prototype is implemented. The optimal values acquired using the sensitivity analysis is then plugged into the hardware prototype and compared with the simulation. The results obtained confirm the validity of the proposed method.

Harave, Sudarshan↗

DOE OSTI2023

A Novel LCC-CLCC Resonant Tuning Network for Light-Load Conditions in Wireless Power Transfer Systems

In wireless power transfer (WPT) systems, voltage and current distortions are observed at the vehicle side rectifier when power flow is from grid to vehicle (G2V) under light load conditions. These distortions can increase switching losses and decrease the overall efficiency of the WPT system. To address this issue, this paper proposes adding a higher value inductor in series with the original LCC tuning network at the vehicle side. However, increasing the series inductance causes the input impedance and phase angle to move away from the resonant frequency. To solve this problem, a capacitor is added in series to tune out the difference between the original and modified inductor values. This series tuning capacitor also improves the power factor and brings the input impedance and phase angle back to the resonant frequency. The traditional LCC-LCC and proposed LCC-CLCC WPT systems are compared and analyzed analytically, and simulated in a MATLAB/Simulink environment to verify parameters such as efficiency and power transfer capacity. An experimental prototype is implemented and compared with the simulation. The obtained results confirm the validity of the proposed method.

Harave, Sudarshan↗

DOE OSTI2026

A Unified Wireless Charger, On-Board Charger, and Auxiliary Power Module for Electric Vehicle Charging Systems

This paper proposes a unified electric vehicle (EV) charging architecture that integrates wireless power transfer (WPT), an on-board charger (OBC), and an auxiliary power module (APM) within a single architecture. By sharing a multi-functional magnetic structure and active switch bridges, the proposed topology eliminates additional transformers and converter stages, reducing hardware complexity and improving power density. A multipurpose magnetic design achieves magnetic decoupling among the WPT, OBC, and APM functions while maintaining the required coupling for each mode. Through electrical reconfiguration, the WPT operates as an LCC-S converter, whereas the OBC and APM operate as dual-active-bridge (DAB) converters. The system supports multiple operating modes, including simultaneous high-voltage and lowvoltage battery charging. Finite-element and circuit simulations verify the magnetic characteristics and system operation, demonstrating the feasibility of the proposed unified architecture for EV charging applications.

Jo, Cheolhui [ORNL] (ORCID:0000000322692434)↗

DOE OSTI2026

Design and Performance Assessment of Intermediary Coils for Misalignment Tolerance Improvement in Wireless Power Transfer Systems

This paper investigates the use of intermediate coils positioned between the primary and secondary coils in Wireless Power Transfer (WPT) systems for electric vehicle (EV) charging, with the objective of improving power transfer efficiency and robustness under misalignment conditions. An optimized 1 kW power system that operates at 85 kHz is developed and the misalignment performance was analyzed and compared with and without intermediate coils. A preliminary increase in efficiency of 2.3% at a misalignment of 52% of the coil radius is shown to be possible for a passive intermediate coil. An experimental prototype is built for design verification.

Sivka, Gozde [ORNL]↗

DOE OSTI2020

Advances in High-Power Wireless Charging Systems: Overview and Design Considerations

Wireless charging systems are foreseen as an effective solution to improve the convenience and safety of conventional conductive chargers. As this technology has matured, recent broad applications of wireless chargers to electrified transportation have indicated a trend toward higher power, power density, modularity, and scalability of designs. In this article, commercial systems and laboratory prototypes are reviewed, focusing mostly on the advances in high-power wireless charging systems. The recent endeavors in magnetic pad designs, compensation networks, power electronics converters, control strategies, and communication protocols are illustrated. Both stationary and dynamic (in-motion) wireless charging systems are discussed, and critical differences in their designs and applications are emphasized. On that basis, the comparisons among different solutions and design considerations are summarized to present the essential elements and technology roadmap that will be necessary to support large-scale deployment of high-power wireless charging systems. The review is concluded with the discussion of several fundamental challenges and prospects of high-power wireless power transfer (WPT) systems. Foreseen challenges include utilization of advanced materials, electric and electromagnetic field measurement and mitigation, customization, communications, power metering, and cybersecurity.

25 ENERGY STORAGE↗

DOE OSTI2020

Phase Shift Control of a Three-Phase Inverter for Balanced Secondary Currents in Misaligned Three-Phase Inductive Power Transfer Systems

This paper presents a strategy for generating fundamental reference voltage commands for a double-sided LCC tuned three-phase wireless power transfer (WPT) system to achieve balanced output currents when the receiver and transmitter are not perfectly aligned. Formulas for translating the normalized fundamental current commands into phase-shift commands for two of the phase legs in a two-level three-phase inverter are derived. The methodology is validated through circuit simulations performed using coupler models derived from finite-element simulations. Simulation results for a 1.5 k W system design are included, which indicate near perfect correction of imbalance in the secondary currents for a typical misalignment case.

Pries, Jason↗

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↗

DOE OSTI2022

Multi-modular capacitive wireless power transfer circuit and related techniques

A high performance kilowatt-scale large air-gap multi-modular capacitive wireless power transfer (WPT) system is provided for electric vehicle (EV) charging. In one particular implementation, the multi-modular system achieves high power transfer while maintaining fringing electric fields within prescribed safety limits. The fringing fields are reduced using near-field phased-array field-focusing techniques, wherein the adjacent modules of the multi-modular system are out-phased with respect to one another. The inter-module interactions in this multi-modular system can be modeled, and an approach to eliminate these interactions in a practical EV charging environment is provided. To illustrate one example implementation, a prototype 1.2-kW 6.78-MHz 12-cm air-gap multi-modular capacitive WPT system comprising two 600-W modules is provided. This prototype system achieves 21.2 kW/m2 power transfer density and a peak efficiency of 89.8%. This multi-modular system also achieves a fringing field reduction of 50% compared to its individual modules.

Afridi, Khurram K.↗

DOE OSTI2020

Charge Management for an Inductively Charged On-Demand Battery-Electric Shuttle Service with High Penetration of Renewable Energy

This paper presents a charge management control strategy for an on-demand battery-electric shuttle van operating at the National Renewable Energy Laboratory (NREL) campus and supported by day-time inductive charging at the vehicle's waiting spot. A new control algorithm has been proposed for reducing the demand charge costs incurred from wireless charging of the on-demand shuttle. A custom controller has been developed to monitor the shuttle, wireless charger, renewable energy generation, and various loads at NREL's campus, and regulate charging behavior for demand response. The intermittent renewable generation and sporadic operation of the on-demand shuttle service contribute to a high level of uncertainty in expected campus load profile, which must be carefully managed. The control algorithm predicts energy profile to estimate the mobility needs of the vehicle and maintain uninterrupted service during operation while still minimizing peak demand. The proposed controller has been designed and optimized using a Simulink model for the entire system. Next, it has been implemented and tested in real-time on the NREL campus. Two primary vehicle-use cases, charge sustaining and charge depletion operation, are tested under different load profiles and drive cycles to assess the controller's effectiveness at reducing peak demand and therefore demand charges. The proposed controller showed robust performance under different driving scenarios with high correlation between simulated and experimental data. The results showed that proper demand response can be achieved with an average of 94% reduction of charging loads during peak demand events.

ADVANCED PROPULSION SYSTEMS,ENERGY STORAGE↗

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 OSTI2021

SiC-Based Wireless Power Transformation for Data Centers & Medium Voltage Applications

Data centers have grown in physical size and their electrical power consumption has grown to levels of several 100kW and approaching 1 GW in large installations. The low voltage electrical distribution inside of Data Centers consists of several conversion stages and a lot of wiring to bring the power from medium voltage (MV) levels outside of the building to the low voltage levels that the servers and racks require. Energy losses during distribution and conversion and high incident arc flash energy levels at the point of use are significant. The electrical distribution system is complex and costly.

24 POWER TRANSMISSION AND DISTRIBUTION↗