Design and implementation of a high misalignment-tolerance wireless charger for an electric vehicle with control of the constant current/voltage charging

Abstract

Abstract Wireless charging of Electric Vehicles (EVs) has been extensively researched in the realm of electric cars, offering a convenient method. Nonetheless, there has been a scarcity of experiments conducted on low-power electric vehicles. To establish a wireless power transfer system for an electric vehicle, optimal power and transmission efficiency necessitate arranging the coils coaxially. In wireless charging systems, coils often experience angular and lateral misalignments. In this paper, a new alignment strategy is introduced to tackle the misalignment problem between the transmitter and receiver coils in the wireless charging of Electric Vehicles (EVs). The study involves the design and analysis of a coil, considering factors such as mutual inductance and efficiency. Wireless coils with angular misalignment are modelled in Ansys Maxwell simulation software. The proposed practical EV system aims to align the coils using angular motion, effectively reducing misalignment during the parking of two-wheelers. This is achieved by tilting the transmitter coil in the desired direction. Furthermore, micro sensing coils are employed to identify misalignment and facilitate automatic alignment. Additionally, adopting a power control technique becomes essential to achieve both constant current (CC) and constant voltage (CV) modes during battery charging. Integrating CC and CV modes is crucial for efficiently charging lithium-ion batteries, ensuring prolonged lifespan and optimal capacity utilization. The developed system can improve the efficiency of the wireless charging system to 90.3% with a 24 V, 16 Ah Lithium Ion Phosphate (LiFePO4) battery at a 160 mm distance between the coils.

Keywords

• Wireless power transfer (WPT)
• Electric vehicle (EV)
• Coil tracking system
• Misalignment tolerant
• Constant current (CC)/Voltage (CV) charging