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Innovative Technology Series Workshop 6 Inductive Power Transfer Presenter: Dr Siu-Chung Wong Department of Electronics and Information Engineering The Hong Kong Polytechnic University 1 Part 1:Introduction 5. Control 6. Design Example 4. Transformer 1. Introduction 3. Compensation Network 2. Basic Analysis 2 Introduction Electric Power Transfer Conventional method: • Metal Conductor Soldering • Electrical Plug and Socket Potentially not safe! • Brush Metal Contact 3 Introduction Conventional Wireless 4 Roadmap of WPT 2010 commercialized First patent Faraday, Law of induction 1831 1891 Tesla Coil 1894 H. J. G. Bolger, F. A. Kirsten and L.S. Ng, “Inductive power coupling for an electric highway system,” Vehicular Technology Conference, Vol. 28, pp.137-144, March 1978 1978 1964, 1968 Micro wave WPT 1990s 1996-EV1, 1987— SHARP SAE J1773 microwave HF IPT airplane 1989-1996 charging of EV USA PATH 1980s A4WP & PMA merge MIT, lighten a 60 W lamp 2 m WPC wireless away charging standard Qi 2010 2007 2008 WPC established 2013 2015 2014 SAE “J2954” for EV/PHEV t(year) IEC61580 Communication standard for EV 1987— implant 1980—Brush replacement 5 WPT classification Inductiveinductive and resonant Capacitive Can penetrate metal, very short distance, high frequency and lower power Inductive— Lower frequency,wider power Long Range — Laser/Microwave Long or very long distance Resonant— Higher frequency, longer distance 6 Capacitive coupling Input voltage: 340V Output voltage: 196V Output current: 5.21A Frequency: 540KHz Efficiency: 83% Air gap: 100um Wireless Electric Vehicle Charging via Capacitive Power Transfer Through a Conformal Bumper Jiejian Dai , Daniel C. Ludois , APEC 2015 7 WPT – Long Range —— Safety issue —— Occupy a lot of space —— higher loss 8 WPT Inductive Power Transfer Japan Airplane IPT Mojo Mobility coils I P T Germany Wampfler WiPower track IPT Splashpower 2000 …… 0.5W Seiko IPT charger 2007 Powermat Japan Haneda Airport Bus IPT 东光 Seiko 2.5 W IPT 2008 IPT Fulton Innovation IPT 2009 2010 Now 9 WPT Inductive Power Transfer Magnetic Resonant WPT 海尔“ 无尾” 电视 USA MIT Intel Japan WPT 2007 2008 2009 2010 Sony WPT Now Less sensitive to transformer misalignment Safety Issue High frequency operation 10 WPT application Industry Cardiac Pacemaker Artificial Heart Medical Home EV charger 11 WPT application 3M—under ground positioning 0.6m-2m HV Reflect Transmit IoT power Underground pipe dection Nina M. Roscoe and Martin D. Judd. Harvesting Energy from Magnetic Fields to Power Condition Monitoring Sensors[J]. Sensors Journal, IEEE ,2013:3 12 WPT standards Qi First international IPT standard; Established from City University Hong Kong then the WPC (wireless power consortium)。 on Sept. 2015,WPC has 217 member。 Google“Nexus”and Nokia“Lumia”support this standard。 13 Corporations PMA(Power Matters Alliance) Rezence (A4WP) merged Initialized by Duracell Powermat; on Sept. 2015, A4WP has 150 members including Qualcomm,Samsung,Broadcom and Intel. Duracell Powermat WiCC card 14 EV charging technology Waseda University Japan KIST, Korea ZTE, China Gap:10cm Gap:26cm Gap:20cm Power:30kW Power:5*20kW Power:30kW Efficiency:92% Efficiency: 80%~85% Efficiency:92% Announced: 2011 Announced:2013 Announced:2014 15 EV charging technology Idaho National Laboratory, USA Qualcomm Gap:11cm Gap: Power:3.3kW Power:7.2kW Efficiency:89.2% Charging Time:1 hour Announced: 2013 Announced:2015 Witricity Operating frequency:85kHz Power:2kW Charging Time: 1.5 hours Announced:2014 16 Installation ABB(Geneve Airport and Palexpo convention center),15 second charging at 400 kW,from top of the bus. 17 Wireless Power Transfer System Primary M Secondary VO ~ Inverter Rectifier Secondary Feedback circuit Controller F/V pack Gap Driver Circuit converter Battery ... PFC Single or Circuit Three phase Filter buffer I T V VCO 18 Critical Technology Electromagnetic compatibility A Communicatio n Material G B WPT Technology F Safety E Transformer Coupling C D Control Circuit Theory and Power Electronics 19 Critical Technology IPT system Primary Primary ~ Inverter Feedback circuit F/V Large parameter variation pack I T Secondary Filter converter Small Coupling Coefficient Battery Gap Controller Secondary VO Rectifier Driver Circuit Gap Secondary ... PFC Single or Circuit Three phase M buffer V VCO Tactic: Inductances compensation Optimization of Transformer Effective control 20 Part 2:Basic Analysis 6. Design Example 1. Introduction 5. Control 2. Basic Analysis 4. Transformer 3. Compensation Network 21 Transformer Model Primary ~ Inverter Transformer model Battery pack I T Gap Secondary Feedback circuit Controller F/V VO Rectifier Driver Circuit converter Secondary ... PFC Single or Circuit Three phase M Filter buffer VCO V Coupling 22 Transformer Equivalent Model Leakage inductance model n: Turns ratio Three parameter model Coupling Model Equivalent n L'L L''L * * 1: n' L'M LP LL1 LM 2 LS LL 2 n LM k M LP LS ' L n S M ' LL1 LS LM LL 2 LP LS M 2 LL L LS S M2 ' LM LS 1: n'' L''M '' M n L P '' M2 LL LS LP L'' L P M 23 Part 3:Compensation network 1. Introduction 2. Basic Analysis 6. Design Example 3. Compensation Network 5. Control 4. Transformer 24 Why compensation? Primary Windings Gap Large leakage inductance and small mutual inductance Secondary Windings Improve input power factor Reduce device rating Improve power transfer Improve efficiency Reduce sensitivity to transformer parameter variation 25 Circuit Power source Inverter Primary Voltage source input Current source input Compensation Rectifier Filter Load Secondary C Filter LC Filter 26 Primary circuit Voltage source input vAB + Capacitor clamped Current source input Capacitor clamped 27 Secondary Circuit C filter,output voltage assumed constant LC filter,output current assumed constant RE Phase of vOR and iare identical,like a resistor。 2 Equivalent load resistor: 4 Vo sin(t ) 4 Vo vOS 8 V 8 RE 2 o 2 RL i2 I 2 sin(t ) I I 2 28 OUTPUT EQUIVALENT RESISTANCE C filter,output voltage assumed constant LC filter,output current assumed constant RE RE 8 2 RL RE 2 8 RL 29 System Simplification Square voltage Square current 30 Resonant Compensation Series resonant Voltage across L C compensated to zero。When high Q,voltages across L and C can be higher than the input。 Q Parallel resonant L R 1 L R C Current flow through L and C cancelled out。 31 Secondary Capacitor Compensation Parallel Reflected Zr: Series Zr Power transfer capability: 1 LS CS Compensation Series Parallel 2 M 2 Primary current: I P ZS V AB j L P Z r P I P2 Re Z r Re(Zr) Im(Zr) Comment 0 Im(Zr)=0 M 2 Capacitive load independent Im(Zr) 2M 2 RE M 2 RE L2S LS 32 Secondary Capacitor Compensation Parallel Series If Ip constant iS LS jωMIP Output current is load independent C i2 + − vOS RE Output voltage is load independent Can have load independent output. 33 Primary Capacitor Compensation Series Parallel and for driving high winding Suitable Suitable for driving large value LP We need primary current to minimize input current. to minimize input driving voltage. secondary compensations 34 Primary and Secondary Compensations 35 Primary and Secondary Compensations 36 Resonant at 40 kHz S/S voltage gain P/P current gain Primary and Secondary Compensations S/P voltage gain P/S current gain 37 S/S Compensation Resonant H Input inductive,current circulating loss Load independent output voltage Even worse at light load Resonant S 2M 2 RE jv AB RE M Low input resistance,small reactance Load independent current output Need open circuit protection 38 S/S compensation Output voltage 408V,output current 66.2A Huh, J.; Lee, S.W.; Lee, W.Y.; Cho, G.H.; Rim, C.T., "Narrow-Width Inductive Power Transfer System for Online Electrical Vehicles," in Power Electronics, IEEE39 Transactions on , vol.26, no.12, pp.3666-3679, Dec. 2011 S/S Compensation Example Output voltage 408V,output current 66.2A S/S uses less copper Sallan, J.; Villa, J.L.; Llombart, A.; Sanz, J.F., "Optimal Design of ICPT Systems Applied to Electric Vehicle Battery Charge," in Industrial Electronics, IEEE Transactions 40 on , vol.56, no.6, pp.2140-2149, June 2009 S/P Compensation C1 LL’ 1:n + vAB + C3 LM’ RE vOS − + S vAB − n' 1:n + RE − vOS − LS M L model C design forvoltage gain, output needs short circuit protection Input zero phase angle 1 PLL control C3design forphase anglemay fail due to high Q at light load Output load independent 4 2.8 2.4 2 RE=400 1.6 1.2 RE=200 0.8 0.4 0 20kHz RE=50 30kHz 40kHz 50kHz Input phase angle Voltage gain 3.6 3.2 60kHz 41 S/P Compensation Example Frequency 22 kHz Kobayashi, K.; Yoshida, N.; Kamiya, Y.; Daisho, Y.; Takahashi, S., "Development of a non-contact rapid charging inductive power supply system for electric-driven 42 vehicles," in Vehicle Power and Propulsion Conference (VPPC), 2010 IEEE , vol., no., pp.1-6, 1-3 Sept. 2010 P/P Compensation Input must be a current M 2 LS I1 jC1 I1 jC1 M 2 RE L2S 2 M RE L2S MI P LS LS I1 j MC1 RE LS C2 S RE Load independent output voltage RE Input capacitive 43 P/P Compensation Example Power:300W,primary current 15A,20kHz,load 6Ω,k=0.45,QS=1.77 Chwei-Sen Wang; Stielau, O.H.; Covic, G.A., "Design considerations for a contactless electric vehicle battery charger," in Industrial Electronics, IEEE Transactions on, 44 vol.52, no.5, pp.1308-1314, Oct. 2005 P/S Compensation + vAB – i1 LP C1 + –jωMIS − Input must be a current source LS C2 M + jωMIP − I1 jC1 RE S I1 jC1 2M 2 RE RE I1 2 MC1 Load independent current output Input capacitive 45 P/S Compensation S C1 design for transfer function, C2 design for input phase angle P 2M 2 RE I1 2 MC1 RE Input capacitive * * M LP * Current input n' I1 jC1 * I1 jC1 P 2 1 LP C1 1 LS M C2 Load independent current output Input zero phase angle 46 S/S Compensation optimization Load independent output and high efficiency Primary Secondary Efficiency set Optimum frequency for maximal efficiency Wei Zhang; Siu-Chung Wong; Tse, C.K.; Qianhong Chen, "Design for Efficiency Optimization and Voltage Controllability of Series–Series Compensated Inductive47 Power Transfer Systems," Power Electronics, IEEE Transactions on , vol.29, no.1, pp.191,200, Jan. 2014 S/S Compensation optimization Load independent output and high efficiency Efficiency at ωM: Efficiency maximized at QO1 Efficiency increase with decreasing QO Wei Zhang; Siu-Chung Wong; Tse, C.K.; Qianhong Chen, "Design for Efficiency Optimization and Voltage Controllability of Series–Series Compensated Inductive48 Power Transfer Systems," Power Electronics, IEEE Transactions on , vol.29, no.1, pp.191,200, Jan. 2014 S/S Compensation optimization Load independent output and high efficiency When QP=QS When λ<1/3 (k<0.577), near load QO1,ωM andωS are nearly identical replaceωM withωS ωS is load independent Efficiency at ωS and ωM With a known load,design a transformer such that ωM ≈ ωS to have maximum efficiency Wei Zhang; Siu-Chung Wong; Tse, C.K.; Qianhong Chen, "Design for Efficiency Optimization and Voltage Controllability of Series–Series Compensated Inductive49 Power Transfer Systems," Power Electronics, IEEE Transactions on , vol.29, no.1, pp.191,200, Jan. 2014 S/S Compensation optimization Load independent output and high efficiency S/S compensation voltage gain: Frequencies: Wei Zhang; Siu-Chung Wong; Tse, C.K.; Qianhong Chen, "Design for Efficiency Optimization and Voltage Controllability of Series–Series Compensated Inductive50 Power Transfer Systems," Power Electronics, IEEE Transactions on , vol.29, no.1, pp.191,200, Jan. 2014 S/S Compensation optimization Load independent output and high efficiency Operating freq. Load independent |Gv| Maximum Eff. ωH ωM ≈ ωS (λ<1/3) ωH cannot be ωS CS design for efficiency CP design for efficiency,such that ωH close toωS Wei Zhang; Siu-Chung Wong; Tse, C.K.; Qianhong Chen, "Design for Efficiency Optimization and Voltage Controllability of Series–Series Compensated Inductive51 Power Transfer Systems," Power Electronics, IEEE Transactions on , vol.29, no.1, pp.191,200, Jan. 2014 S/S Compensation optimization Load independent output and high efficiency Define : CP=1.1CPn ηT CP=1.3CPn 2 1 ηT 2 1 0.8 1.6 0.8 1.6 0.6 1.2 |Gv 0.6 | 1.2 0.4 0.8 0.4 0.8 0.2 0.4 0.2 0.4 0 100k 125k 150k 175k Frequency 0 200k 0 100k 125k 150k 175k |Gv | 0 200k Frequency Design Cp makingωH closer toωS to have a higher efficiency maximize efficiency of S/S compensated converter to have load independent output Wei Zhang; Siu-Chung Wong; Tse, C.K.; Qianhong Chen, "Design for Efficiency Optimization and Voltage Controllability of Series–Series Compensated Inductive52 Power Transfer Systems," Power Electronics, IEEE Transactions on , vol.29, no.1, pp.191,200, Jan. 2014 S/S Compensation optimization Load independent output and high efficiency 2M 2 RE jv AB RE M If a constant output current is needed,S/S compensation should operate at ωS. Proper output open circuit protection should be given. 53 Realization of Load Independent Output iS LS jωMIP C i2 + − vOS RE Voltage source output Current source output 54 Realization of Input Current Primary side LCL compensation LP Lr + vAB C1 ip -jωMIS Norton Eq. Lr C1 + jωMIP − − LP LS + + − v AB j Lr is M ip + LS + + -jωMIS jωMIP − − vOS - is M Secondar y Compens ation vOS - 55 Primary and Secondary LCL Compensation IT is load independent and so is IO Suitable for multiple secondary windings application LCL need external indicator as large as LM,lower system power density. 56 LCC COMPENSATION LP’ ip ieq Minimize Lf CP -jωMIS LP' LP 1 2CS1 Compared with LCL compensation,LCC compensation can have VAB higher injected current. Ieqv j LP 1 2CS1 Current gain (normally less than 3 due to magnetics): Qi 1 C1 CS1 C1 Esteban, B.; Sid-Ahmed, M.; Kar, N.C., "A Comparative Study of Power Supply Architectures in Wireless EV Charging Systems," Power Electronics, IEEE Transactions 57 on , vol.30, no.11, pp.6408,6422, Nov. 2015 LCC COMPENSATION Parallel capacitor Cf reduce inductance Lf; Load independent current output; Siqi Li; Weihan Li; Junjun Deng; Nguyen, T.D.; Mi, C.C., "A Double-Sided LCC Compensation Network and Its Tuning Method for Wireless Power Transfer," Vehicular 58 Technology, IEEE Transactions on , vol.64, no.6, pp.2261,2273, June 2015 LCC COMPENSATION-INTEGRATED Magnetic coupling can improve power density。 Coupling Circuits Weihan Li; Han Zhao; Siqi Li; Junjun Deng; Tianze Kan; Mi, C.C., "Integrated LCC Compensation Topology for Wireless Charger in Electric and Plug-in Electric 59 Vehicles," Industrial Electronics, IEEE Transactions on , vol.62, no.7, pp.4215,4225, July 2015 LCC COMPENSATION-INTEGRATED Coupling Equivalent Matching: Weihan Li; Han Zhao; Siqi Li; Junjun Deng; Tianze Kan; Mi, C.C., "Integrated LCC Compensation Topology for Wireless Charger in Electric and Plug-in Electric 60 Vehicles," Industrial Electronics, IEEE Transactions on , vol.62, no.7, pp.4215,4225, July 2015 SP/S Compensation Primary parallel compensation Primary series compensation LP ip + vAB 1 2M 2 Z in j LP RP jCP ZS Z in LS + + CP -jωMIS jωMIP − − - is M 1 jCP 1 j LP RP 2M 2 ZS Misalignment, coupling reduced Primary series compensation Primary parallel compensation combine IP increases,can be over current. Is may also increases. IP decreases,so as Is. Villa, J.L.; Sallan, J.; Sanz Osorio, J.F.; Llombart, A., "High-Misalignment Tolerant Compensation Topology For ICPT Systems," Industrial Electronics, IEEE Transactions 61 on , vol.59, no.2, pp.945,951, Feb. 2012 SP/S Compensation 原边串联电容将虚部补偿掉。 Input power Load power Villa, J.L.; Sallan, J.; Sanz Osorio, J.F.; Llombart, A., "High-Misalignment Tolerant Compensation Topology For ICPT Systems," Industrial Electronics, IEEE Transactions 62 on , vol.59, no.2, pp.945,951, Feb. 2012 SP/S Compensation Input zero phase angle; Insensitive to misalignment。 Input resistance change with output load。 Villa, J.L.; Sallan, J.; Sanz Osorio, J.F.; Llombart, A., "High-Misalignment Tolerant Compensation Topology For ICPT Systems," Industrial Electronics, IEEE Transactions 63 on , vol.59, no.2, pp.945,951, Feb. 2012 S/S AND S/P COMPENSATION Ll 2 Voltage gain a function of n only 1 C2 + vAB LM - vOS RE - 1 C1 n 2 L'M n' 1:n Input inductive L'l S/P compensation + i2 * S/S compensation i1 * 1 Ll1 C1 1 C2 LS n L 1 (假设 P 2 ) M k LS n Input resistive Voltage gain a function of n and k Hou Jia,Chen Qianhong,Wong Siu-Chung,Tse Chi. K.,Ruan Xinbo.Analysis and control of series/series-parallel compensated resonant converter for contactless 64 power transfer[J].IEEE Journal of Emerging and Selected Topics in Power Electronics,2015,3(1):124-136. S/SP COMPENSATION Z1 C1 LL1 v LM LL2 C2 1:n + vAB Z2 LM − Compensation: 2 + C3 RE vOS − 1 1 1 2 Ll1C1 Ll 2 C2 n LM C3 Voltage gain a function of n only Input resistive Hou Jia,Chen Qianhong,Wong Siu-Chung,Tse Chi. K.,Ruan Xinbo.Analysis and control of series/series-parallel compensated resonant converter for contactless 65 power transfer[J].IEEE Journal of Emerging and Selected Topics in Power Electronics,2015,3(1):124-136. S/SP COMPENSATION Voltage gain 8 n Gv 2 j C3 Z1 Z 3 Z1 j LM Z 2 j LM j LM = 4C p Cs (n 2 L2M Lp Ls )+ 2 (Lp C p Ls Cs ) 1 Voltage gain at Gv i 8 2 j 3C1C2 LM RE △=0,gain becomes load independent n 1 i LM 1 LL1C1 1 LL2 C2 1 : Z in i n L 2 2 M Gv i Finally: n 2 LM C3 1 Z in j LP jC1 j L S Input impedance Input impedance at If 0,gain becomes LM independent C3 Z1 Z 3 Z1 ji LM Z 2 8 2 n 2M 2 1 1 || RE jC2 jC3 j LM RE C3 1 RE j n LM 2 RE n2 If 0, then a pure resistor 66 S/SP COMPENSATION Resonant frequency Compensation capacitor Transformer parameter RL fr = 40 kHz C1 = 48.89nF, C2 = 44.2nF, C3 = 51.4nF 10 cm: kmax = 0.475, Ll1 = 324.967 , Ll2 = 362.56 , LM = 310.948 20 cm: kmin = 0.231, Ll1 = 435.275 , Ll2 = 462.95 , LM = 134.85 RLmin = 100 Ω, RLmid = 400 Ω, RLmax = 800 Ω 10 8 Constant freq. 6 control Gv 4 fL_kmax 23.7k 2 0 20 fH_kmax 40k 30 40 fs(kHz) 50 60 67 S/SP COMPENSATION Fundamental approximation is not able to keep up with the accuracy. 。 Lot of higher harmonics 68 Higher Harmonic Equivalent Circuit Input voltage: VAB _ m Output current: I 2 _ m 4Vin m 4I o m 69 Higher Harmonic Equivalent Circuit Input voltage: VAB _ m Output current: I 2 _ m Voltage across LM m=1: m=3,5,7,9,…: VLM _1 VAB _1 VLM _ m VAB _ m 4Vin m 4I o m k vLM t 1 k VAB _1 sin s t kv AB t sine square Secondary current m=1: 1 I S _1 nVAB _1 jr C3 Z E _1 iS t I S _1 sin s t 1 m=3,5,7,9,…: IS _ m 0 sine 70 Waveforms of Resonant Circuit sine square vLM t 1 k VAB _1 sin s t kv AB t iS t I S _1 sin s t 1 sine iLM 71 Output Waveforms Output current harmonics Harmonic current and voltage 72 Experimental Comparisons Po =1.5 kW 39.2kHz Po =0.8 kW Input current Voltage across parallel capacitor 73 S/SP COMPENSATION 0.82 Gv 0.8 0.78 Result from calculation with Fundamental approximation Result from calculation with higher harmonics 0.76 Experimental result 0.74 200 300 500 700 900 Po(W) 1100 1300 1500 74 Switching of Series or Parallel Compensation on the Secondary Side Battery charging needs two stages: Constant Current,until battery reach a voltage level, Constant voltage,until current diminishing to nearly none. Constant voltage , S1 and S2 open, S3 connects RL to L2,forming a S/S compensation,Ls = L1 + L2(dotted blue) Constant current , S1 and S2 close, S3 connects RL in parallel with Cssp ,forming a S/P compensation, Ls = L1。(solid red) Auvigne, C.; Germano, P.; Ladas, D.; Perriard, Y., "A dual-topology ICPT applied to an electric vehicle battery charger," Electrical Machines (ICEM), 2012 XXth International Conference on , vol., no., pp.2287,2292, 2-5 Sept. 2012 75 DYNAMIC TUNING When there are variation of parameters, such as load, coupling and driving frequency,system compensation may deviate from optimal point. a Soft-Switched Variable Inductor inside the resonant circuit Hu, A.P.; Hussmann, S., "Improved power flow control for contactless moving sensor applications," Power Electronics Letters, IEEE , vol.2, no.4, pp.135,138, Dec.76 2004. doi: 10.1109/LPEL.2004.841311 DYNAMIC TUNING Use extra inductor or capacitor; Need bidirectional current switch; Discrete alteration of Capacitance or inductance. Three mode boost inductor secondary compensation freewheeling period Z. Pantic and S. M. Lukic, “A new tri-state-boost-based pickup topology for inductive power transfer applications,” in Proc. IEEE Energy Convers. Congr. Expo., Phoenix, AZ, Sep. 2011, pp. 3495–3502. Pantic, Z.; Lukic, S.M., "Framework and Topology for Active Tuning of Parallel Compensated Receivers in Power Transfer Systems," Power Electronics, IEEE Transactions 77 on, vol.27, no.11, pp.4503,4513, Nov. 2012 Part 4:Transformer Optimization 2. Basic Analysis 1. Introduction 3. Compensation Network 4. Transformer 6. Design Example 5. Control 78 79