Figure 1.
Loss calculation formula of each part in the magnetic coupler.
Figure 1.
Loss calculation formula of each part in the magnetic coupler.
Figure 2.
Schematic diagram of solid copper wire’s skin effect and proximity effect. (a) Skin effect; (b) proximity effect.
Figure 2.
Schematic diagram of solid copper wire’s skin effect and proximity effect. (a) Skin effect; (b) proximity effect.
Figure 3.
Schematic diagram of single layer square solenoid coil. (a) Real solenoid coil; (b) simplified solenoid coil model.
Figure 3.
Schematic diagram of single layer square solenoid coil. (a) Real solenoid coil; (b) simplified solenoid coil model.
Figure 4.
Change curve of copper resistivity with temperature.
Figure 4.
Change curve of copper resistivity with temperature.
Figure 5.
Hysteresis loop.
Figure 5.
Hysteresis loop.
Figure 6.
B-P curve data fitting of magnetic ferrite core.
Figure 6.
B-P curve data fitting of magnetic ferrite core.
Figure 7.
Cloud diagram of the magnetic induction intensity distribution in the magnetic coupler under different conditions. (a) Magnetic induction intensity distribution without aluminum plate; (b) magnetic induction intensity distribution with aluminum plate.
Figure 7.
Cloud diagram of the magnetic induction intensity distribution in the magnetic coupler under different conditions. (a) Magnetic induction intensity distribution without aluminum plate; (b) magnetic induction intensity distribution with aluminum plate.
Figure 8.
Schematic diagram of a geometric model of shielding aluminum plate.
Figure 8.
Schematic diagram of a geometric model of shielding aluminum plate.
Figure 9.
Variation of aluminum plate loss with aluminum plate conductivity.
Figure 9.
Variation of aluminum plate loss with aluminum plate conductivity.
Figure 10.
Loss distribution diagram of the aluminum plate in simulation results.
Figure 10.
Loss distribution diagram of the aluminum plate in simulation results.
Figure 11.
Grid division of aluminum plate.
Figure 11.
Grid division of aluminum plate.
Figure 12.
Variation curve of aluminum resistivity with temperature.
Figure 12.
Variation curve of aluminum resistivity with temperature.
Figure 13.
Schematic diagram of heat transfer mode of the magnetic coupler.
Figure 13.
Schematic diagram of heat transfer mode of the magnetic coupler.
Figure 14.
The temperature of each part of the primary magnetic coupler. (a) Primary coil; (b) primary magnetic core; (c) primary aluminum plate; (d) primary cover plate; and (e) primary wire tray.
Figure 14.
The temperature of each part of the primary magnetic coupler. (a) Primary coil; (b) primary magnetic core; (c) primary aluminum plate; (d) primary cover plate; and (e) primary wire tray.
Figure 15.
The temperature of each part of the secondary magnetic coupler. (a) Secondary coil; (b) secondary magnetic core; (c) secondary aluminum plate; (d) secondary cover plate; and (e) secondary wire tray.
Figure 15.
The temperature of each part of the secondary magnetic coupler. (a) Secondary coil; (b) secondary magnetic core; (c) secondary aluminum plate; (d) secondary cover plate; and (e) secondary wire tray.
Figure 16.
The magnetic coupler’s thermal design steps.
Figure 16.
The magnetic coupler’s thermal design steps.
Figure 17.
Variation of the maximum temperature of each part of the magnetic coupler with supporting material. (a) Primary magnetic coupler; (b) secondary magnetic coupler.
Figure 17.
Variation of the maximum temperature of each part of the magnetic coupler with supporting material. (a) Primary magnetic coupler; (b) secondary magnetic coupler.
Figure 18.
Variation of the maximum temperature of each part of the magnetic coupler with emissivity of the aluminum plate. (a) Primary magnetic coupler; (b) secondary magnetic coupler.
Figure 18.
Variation of the maximum temperature of each part of the magnetic coupler with emissivity of the aluminum plate. (a) Primary magnetic coupler; (b) secondary magnetic coupler.
Figure 19.
A 6.6 kw electric vehicle wireless charging system experimental platform.
Figure 19.
A 6.6 kw electric vehicle wireless charging system experimental platform.
Figure 20.
Loss ratio of simulation and experiment. (a) Loss ratio of the experiment; (b) loss ratio of simulation.
Figure 20.
Loss ratio of simulation and experiment. (a) Loss ratio of the experiment; (b) loss ratio of simulation.
Figure 21.
Embedded position of thermocouple sensors. (a) Primary coil; (b) primary magnetic core; (c) primary aluminum plate; (d) secondary coil; (e) secondary magnetic core; and (f) secondary aluminum plate.
Figure 21.
Embedded position of thermocouple sensors. (a) Primary coil; (b) primary magnetic core; (c) primary aluminum plate; (d) secondary coil; (e) secondary magnetic core; and (f) secondary aluminum plate.
Figure 22.
The temperature of the secondary shielding aluminum plate of the magnetic coupler. (a) The shielding aluminum plate; (b) the temperature value and distribution of the shielding aluminum plate.
Figure 22.
The temperature of the secondary shielding aluminum plate of the magnetic coupler. (a) The shielding aluminum plate; (b) the temperature value and distribution of the shielding aluminum plate.
Figure 23.
Temperature curve of each part of the magnetic coupler. (a) Temperature curve of each part of the primary side; (b) temperature curve of each part of the secondary side.
Figure 23.
Temperature curve of each part of the magnetic coupler. (a) Temperature curve of each part of the primary side; (b) temperature curve of each part of the secondary side.
Figure 24.
The temperature of secondary shielding aluminum plate coated with thermal conductive silicone grease. (a) Shielding aluminum plate coated with thermal conductive silicone grease; (b) temperature value and distribution.
Figure 24.
The temperature of secondary shielding aluminum plate coated with thermal conductive silicone grease. (a) Shielding aluminum plate coated with thermal conductive silicone grease; (b) temperature value and distribution.
Table 1.
Electromagnetic field material parameters of the magnetic coupler’s coil, core, and aluminum plate.
Table 1.
Electromagnetic field material parameters of the magnetic coupler’s coil, core, and aluminum plate.
Category | Coil | Magnetic Core | Aluminum Plate |
---|
Conductivity (S/m) | 58,000,000 | 1.00 | 38,000,000 |
Relative permeability | 0.99 | 3300 | 1.00 |
Relative dielectric constant | 1.00 | 12 | 1.00 |
Table 2.
Thermal field material parameters of the magnetic coupler’s coil, core, and aluminum plate.
Table 2.
Thermal field material parameters of the magnetic coupler’s coil, core, and aluminum plate.
Category | Coil | Magnetic Core | Aluminum Plate |
---|
Specific heat capacity (J/(kg∙K)) | 390 | 750 | 880 |
Density (kg/m3) | 8933 | 4600 | 2700 |
Thermal conductivity (W/m∙K) | 387.6 | 4 | 240 |
Table 3.
Parameters of supporting materials.
Table 3.
Parameters of supporting materials.
Category | Polystyrene | Teflon | FR4 | Bakelite |
---|
Thermal conductivity (W/m∙K) | 0.14 | 0.24 | 0.35 | 0.50 |
Emissivity | 0.86 | 0.86 | 0.90 | 0.90 |
Table 4.
Main parameters of each part of the magnetic coupler.
Table 4.
Main parameters of each part of the magnetic coupler.
Parameter | Primary Side | Secondary Side |
---|
Coil winding form | Double strand parallel winding for 8 turns | Double strand parallel winding for 10 turns |
Turn spacing | 6.5 mm | 1 mm |
Wire width | 180 mm | 109 mm |
Wire diameter | 5 mm | 5 mm |
Core size | 650 mm × 510 mm | 350 mm × 350 mm |
Core thickness | 5 mm | 5 mm |
Aluminum plate size | 675 mm × 535 mm | 375 mm × 375 mm |
Aluminum plate thickness | 3 mm | 2 mm |
Table 5.
Loss of each part of the magnetic coupler.
Table 5.
Loss of each part of the magnetic coupler.
Category | Simulated Loss Value (W) | Experimental Loss Value (W) |
---|
Primary coil | 58.23 | 51.00 |
Primary core | 78.80 | 79.21 |
Primary aluminum plate | 38.81 | 115.31 |
Secondary coil | 50.59 |
Secondary core | 9.74 |
Secondary aluminum plate | 13.50 |
Table 6.
Temperature of each part of the magnetic coupler.
Table 6.
Temperature of each part of the magnetic coupler.
Value | Simulated Temperature (°C) | Experimental Temperature (°C) |
---|
Primary coil | 49.69 | 48.9 |
Primary core | 43.68 | 46.2 |
Primary aluminum plate | 40.01 | 44.1 |
Secondary coil | 76.79 | 73.6 |
Secondary core | 70.66 | 68.7 |
Secondary aluminum plate | 45.98 | 42.8 |