Covic IPT Powering Our Future PDF

Inductive Power Transfer (IPT)
Powering our future

Grant Covic
Professors Grant Covic and John Boys
Power Electronics Research Group
Department of Electrical and Computer Engineering
The University of Auckland, New Zealand
What is Inductive Power
Transfer?
Contacts: j.boys@auckland.ac.nz or ga.covic@auckland.ac.nz
Copyright Auckland Uniservices Ltd. 2010
All Rights Reserved
Ampere and Faraday:
Founders of Electrical Engineering
Michael Faraday:
Discovered electricity could be
generated by mechanical machines.
Andre-Marie Ampere:
Proposed that magnetic fields and
electric currents must exist together.
Electricity: the underpinning technology of our
society.
All Rights Reserved
The Concept of IPT
It is a poor transformer
But allows movement and tolerant of misalignment
V
I
H
Ampres Law
Faradays Law
All Rights Reserved
Light Bulb Demonstration
All Rights Reserved
Motivation wires are messy
Wireless Power
All Rights Reserved
Motivation wires are not secure
All Rights Reserved
Motivation power to moving vehicles
Galvanic isolation
Unaffected by dirt, water, chemicals
Particularly clean producing no residues
No trailing wires
No sliding brushes
Maintenance free
All Rights Reserved
3C
Input
track conductor inductance
I
Switched
Mode
Controller
DC
Pick-up
Compensation
Pick-up
Inductance
Power
Power Supply
+ Output
Compensation
Litz Wire
Power Electronics
Modern Microprocessor Controllers
Modern Ferrites
Concept Design of an IPT System
All Rights Reserved
1990: Our first IPT System
2mm Operating air-gap
Alignment non critical
No power regulation
Maximum 1 trolley/track
Large pick-up coil
Low efficiency
But it worked!!!
100 pair telephone cables
Brushless DC Driving Motor
All Rights Reserved
Prototype Comparison
Original System Daifuku Prototype
Power rating 1W 400 W
Efficiency <10% 85%
# of Carriers 1 3
Load 75 kg 250 kg
Speed 0.1 m/s 1 m/s
Track current 80A 80A
Track length 3 m 25 m
Air-gap 2 mm 4 mm
All Rights Reserved
Our Situation:
15 month old toy system
No appreciation of the inherent difficulties in
the task
No idea about controllers or decoupling
Had to produce a 3-trolley system in 4
months!
All Rights Reserved
Conceptual System Structure:
All Rights Reserved
Daifuku:
excellent partner eg monorail section
All Rights Reserved
1-metre length
All Rights Reserved
Pick-up development:
Wood and ferrite rods
All Rights Reserved
Cut toroidal cores
All Rights Reserved
ETD-49 System: Stage 1
All Rights Reserved
All Rights Reserved
All Rights Reserved
ETD-49 System: Completed
All Rights Reserved
Custom Ferrite Solution
All Rights Reserved
Custom Ferrite System Assembled
All Rights Reserved
Pick-up Mounted on Monorail
All Rights Reserved
Complete Pick-up System
All Rights Reserved
Complete Ramrun System
All Rights Reserved
Aluminum Monorail
Pick-up Coil
Ferrite E
Core
Track Wires
Allows movement
Tolerant of misalignment.
Unaffected by the environment
Prototype Operation
Fundamentals of IPT
All Rights Reserved
Fundamentals of IPT
There are two observables in an IPT System
The Open Circuit voltage:
The Short Circuit Current:
They cannot be observed at the same time.
1
MI j V
OC
e =
2 1
L M I I
SC
=
All Rights Reserved
The Basic IPT Power Equation
2
1
2
2
2
1 1
I
L
M
j
L
M
I MI j S
u
e e = =
All Rights Reserved
The Need for a Tuned Load
jMI
1
R
L
V
2
C
L
2
I
2
jMI
1
R
L
V
2
L
2
I
2
C
To increase the power
Tune at the track frequency
Parallel Tuned
Acts like a current source
Series Tuned
Acts like a voltage source
e e = = C L
2 0
1
All Rights Reserved
The Effect of Tuning
Tuning Boosts power by Q:
But Secondary VA:
But decreases bandwidth by Q:
Reflected impedance onto the track is:
Load dependant
Tuning dependant
Q S P
u
=
Q BW e =
PQ VA~
All Rights Reserved
The Effect of Tuning:
Power boost & Bandwidth
I
sc R
L
V
2
C L
2
I
2
Z
jMI
1
R
L
V
2
C
L
2
I
2
Q BW e =
sc
2
2 sc
2
L 2
1
I s
C
V I Z
1 1
s s
R C L C
= =
+ +
( )
0
0
2 2
0
0
H s
Q
H s
s s
Q
e
=
e
+ + e
Parallel tuned example
c.f. with second order band-pass filter
0
sc
2 sc 0 2 oc
s
0
I Q
V I L Q QV
C
=e
= = e =
e
Maximum power point
0 2
0 L L
L 1
Q
CR R
e
= =
e
0.00
1000
e
0 log(e)
V
2
V
max
max
V 2
BW
All Rights Reserved
Power Fundamentals
Tuned power is dependent on:
Frequency
Track current
Magnetic Coupling
Secondary Tuning Factor
Q
L
M
I Q S P
u
2
2
2
1
e = =
All Rights Reserved
For increased Power:
Operate at a higher frequency
60Hz to 30kHz gives 500 x more power
IPT is impractical at utility frequencies!
Increase the coupling
Elegant solution. Creative!
Increase Q
Q > 5 is difficult to maintain
Increase I
1
Use a larger hammer! More cost, less efficient.
All Rights Reserved
Our first Practical IPT System
Developed for Daifuku
Agreed minimum specification
Huge control problem unknown at the start
Became the cornerstone of their business.
Technology called RAMRUN-HID
All Rights Reserved
Early supplies & instabilities
Early power supplies
had a significant
control problem
The supply frequency
varies with changes in
Track L
1
Tuning capacitor C
1
.
All Rights Reserved
Bifurcation:
With variable frequency supplies
For stability:
total load power x Q < the track VA.
Light Load Heavy Load
All Rights Reserved
The Effect of Tuning:
Reflected impedance
( )
2
2
2
2
( )
ro r o o
M
Z Z R j L
L
e e e = = =
2
2 2
R series tuned
R
parallel tuned
1 1
eq
eq L
Z
L
j
Q Q
e
=

+
+ +
jMI
1
R
L
V
2
C
L
2
I
2
jMI
1
R
L
V
2
L
2
I
2 C
Load Impedance based on tuning
Reflected impedance to track
Parallel tuned reflected impedance at resonance
Parallel tuned
Series tuned
All Rights Reserved
A Decoupling Controller
Controls and helps prevents bifurcation
2
2
eq
2
2
8
(1 ) inductive filter
R
capacitive filter
8
L
L
R
D
R
D
t
t

All Rights Reserved
Research Goals
Eliminate Wires
Make IPT systems
universally available
Lower cost
Higher power
More versatile
Develop the science of IPT
Reduce to engineering practice
Develop standards
Increase the applications
Home use
Medical
Disability aids
Q
L
M
I Q S P
u
2
2
2
1
e = =
All Rights Reserved
The Power Supply
All Rights Reserved
Power Supplies today:
Single phase
N
E
[H]
Fuse
101
109
104
106
108
105
103
102
Line filter
107
50Hz envelope
20kHz IPT power signal
110
Track current
Single phase IPT dynamic controller
All Rights Reserved
Power Supplies today:
3-phase
R
Y
[H]
501
509
504
506
508
505
503
502
3 phase line filter
507
B
E
Frequency
switching
Frequency
Measurement
511
601
510
pick-up coil
Three phase IPT dynamic controller
All Rights Reserved
The Pick-up Regulator
All Rights Reserved
Other Decoupling Controllers
Series tuned
Unity Power Factor (LCL)
All Rights Reserved
Control Characteristics
Basic Equations
Power in terms of Q
Power in terms of D
What is the best controller switching frequency?
Q
L
M
I P
2
2
2
1
e =
) 1 (
2 2
2
1
D V
L
M
I P
o
=
t
All Rights Reserved
Effect of Switching Frequency
100Hz Switching
0
10
20
30
40
50
60
70
0 20 40 60 80 100 120
Duty Cycle (%)
O
u
t
p
u
t

P
o
w
e
r

(
W
)
15kHz Switching
0
10
20
30
40
50
60
70
0 20 40 60 80 100 120
Duty Cycle (%)
O
u
t
p
u
t

P
o
w
e
r

(
W
)
50kHz Switching
0
10
20
30
40
50
60
70
0 20 40 60 80 100 120
Duty Cycle (%)
O
u
t
p
u
t

P
o
w
e
r

(
W
)
100kHz Switching
0
10
20
30
40
50
60
70
0 20 40 60 80 100 120
Duty Cycle (%)
O
u
t
p
u
t

P
o
w
e
r

(
W
)
All Rights Reserved
Transient Response at 30 kHz
Controller Switching Frequency:
The damping factor is very low
Avoid resonating L
DC
with AC tuning C
2
Step response (D =0.50)
All Rights Reserved
The Magnetics
All Rights Reserved
System Coupling
Closely coupled
Transformer
Induction Motor
System Coupling Factor
k typically > 0.98
2 1
L L
M
k =
All Rights Reserved
IPT Systems
Loosely coupled: k < 0.05
Supply Current sourced
Independent secondaries
Efficiency high under load (0 at no load)
Often no primary core
Secondary can move
3C
Input
Power
Supply
track conductor inductance = L
1
I
1
Switched-
Mode
Controller
L
2
DC
power
Tuned
Pickup
Pickup
Inductance
All Rights Reserved
System Coupling
Individual k very low < 0.05
Primary recessed in floor: flat pick-ups
Rail mounted systems: E-core
k typically < 0.5
k n k
n
=
Individual k < 0.1
All Rights Reserved
Understanding Coupling
M
L
1
L
2
Load
Secondary
Compen-
sation
Secondary
Power
Control
VLF
Power
Supply
Utility
Supply
Primary
Compen-
sation
leakage
Elongated Track
leakage
k is a system co-efficient
doesnt fairly represent how good the pick-up is
Kappa looks at coupling without leakage
2 1
L L
M
k =
All Rights Reserved
Problem: Flux Cancellation in E-Pick-up
B-A
Track
Conductor A
(excited)
Track
Conductor B
(not excited)
L2-A
lA
Track
Conductor A
(excited)
Track
Conductor B
(excited)
L2-A
lA
L2-B
lB
} {
} {
A c
A B c
ICCF
u
u
=

} { } { 2 } { lA c A B c A L A c
u + u + u = u

Improving the Magnetic Design
All Rights Reserved
Pickup design: E to S Core
Solution: remove the Flux Cancellation Path
All Rights Reserved
Pickup design: S Core
no cancelation path but more difficult to use
Solution: remove the Flux Cancellation Path
All Rights Reserved
S-pickup on ICPT track
Pick-up Design: FEM Analysis
All Rights Reserved
I=80A
f=10kHz
Coils added to ferrites
Coil current densities (short circuit)
All Rights Reserved
Uncompensated power comparison
e =
B rms ave rms OC
A B N V
) .( ) (
) ( ) ( rms SC rms OC u
I V S =
N
A J
I
I rms ave
rms SC

=
) .(
) (
S-Pickup E-Pickup
V
oc (rms)
35.7 V 20.1 V
I
sc (rms)
4.4 A 4.0 A
S
u
158.5 VA 80.8 VA
S-pickup is composed of the same amount of ferrite
IPT Track Applications
All Rights Reserved
State of the Art Examples
Selected Commercial Licensees of Auckland Uniservices
Daifuku Factory automation (AFA)
Daifuku Clean room (eFA)
Conductix-Wampfler floor systems
3I Innovations - Traffic systems
These applications would not exist without the research
done at The University of Auckland
All Rights Reserved
Factory Automation
Daifuku: HID Automotive & AGVs
100m Sections
10 trolleys @ 750W
AGV 3kW
Batteries
V 30mm
L +/- 30mm
All Rights Reserved
Factory Automation:
Skillets Hoists and AGVs
Daifuku HID
All Rights Reserved
Electronic Factory Automation
Daifuku: Clean Room Systems
All Rights Reserved
Materials Handling:
Conductix-Wampfler: IPT Track
Floor Conveying System
Engine Assembly Lines
AUDI and BMW
Germany
58 vehicles
Track length ~ 2 x 180m
35 vehicles
Track length ~ 150 m
1.5 kW per vehicle for
drive lift & swivel motors
All Rights Reserved
Materials Handling:
Conductix-Wampfler: IPT Track
15 vehicles
6.6 kW each
Track length ~75 m
Floor Conveying System
BMW, Germany
All Rights Reserved
3I Innovations Roadway Systems
Roadway Lighting
Tunnel (Wellington NZ)
Double left turn (Illinois USA)
Tunnel (Sydney Australia)
IPT Roadway Applications
All Rights Reserved
The Arguments
are not simply stationary or moving
All Rights Reserved
Real and Perceived Problems
The need to plug-in represents one of the greatest
challenges to creating a SAFE, convenient and cost
effective EV infrastructure...
All Rights Reserved
Core Advantages
SAFETY
Wireless transfer is safe
Does not harm humans or animals (meets cert.)
Removes electrocution danger
Cannot corrode/short circuit
No tripping hazard
High Power Transfer (10kW)
Double Isolated
EASE OF USE
No plugging or unplugging
Cannot get dirty from cord
Select charging & data options without leaving car
Dont need to brave weather to activate charging
Auto charging (cant forget to plug in)
Fast & slow charging with one system
All Rights Reserved
Core Advantages
DURABILITY
No moving parts
Extremely rugged and tough
Waterproof, weatherproof
Impervious to chemicals, debris
Low profile, crash-safe
Vandal-proof, theft-proof
No cord to steal or unplug
AESTHETICS
Doesnt damage historic city aesthetics
Avoids unnecessary street clutter
Maintains precious footpath area
Eyesore of overhead cables is removed
Provides a subtle branding option for networks
Overview of a Stationary
Charging System
The University of Auckland
All Rights Reserved
How it Works with Electric Vehicles
All Rights Reserved
Power supply
Transmitter
All Rights Reserved
Power supply
Transmitter
Magnetic field
Receiver
Data Transmission
All Rights Reserved
Power supply
Transmitter
Magnetic field
Receiver
Data Transmission
Controller
Battery
All Rights Reserved
Power supply
Transmitter
Magnetic field
Receiver
Data Transmission
Controller
Battery
User Interface
All Rights Reserved
Power supply
Transmitter
Magnetic field
Receiver
Data Transmission
Controller
Battery
User Interface
Multiple transmitters
Development of Stationary
Applications
All Rights Reserved
Commercial
Inductive Chargers
All Rights Reserved
EV1 Battery Charger:
Charging Paddle system
All Rights Reserved
200W Shopping Basket Chargers
Charging Mat in Walmart USA
IPT powered shopping baskets
Power pad sited under trolley
Charging Station
All Rights Reserved
200W Shopping Basket Chargers
Charging Mat in Walmart USA
IPT powered shopping baskets
Power pad sited under trolley
Charging Station
All Rights Reserved
20kW Bus Charge
Series resonant supply
Charging bays
Rapid charging
Computer controlled
20kW charge 7min/20min
3kW pick-ups
10 per vehicle
5 vehicles
Whakarewarewa
Rotorua Charging Bay
Conductix- Wampfler: operated 1997-2007
All Rights Reserved
State of the Art
Conductix-Wampfler: Charging- discontinuous power transfer
Primary side control and Hydraulic levitation
Communications system required
Only application for 1 to 1 application
All Rights Reserved
State of the Art
Conductix- Wampfler: Charging Pick-ups
30kW Pickup
3kW Pickup
20% Duty Cycle
300/600V Output
Nom. Distance to Ground: 30mm
Tolerances: H/L+/-50mm; V +/-10mm
IP 67 -20C / +50C
70 kg, 1025 x 875 x 61mm
All Rights Reserved
30-60kW Bus Charging
Conductix-Wampfler: released 2000
Genoa, Porto Antico
3 buses each with 56 x 6V Batteries
Charging 60kW for 10 minutes/hour
All Rights Reserved
State of the Art
Weil-am-Rhein
Primary Coils
Pickups
Energy Supply (Current)
Cooling System (Water)
Conductix-Wampfler: 60kw Charging station
All Rights Reserved
M
60kW Bus Charge
Genoa, Porto Antico
Supporting Frame
for Pickup
Lowering Mechanism for
Pickup (customer)
30 mm (max)
M
Conductix-Wampfler: released 2000
A working EV Charger using
Inductive Pads
All Rights Reserved
Power Pad - Development
All Rights Reserved
Power Pad - Requirements
Robust
Thin and Light
Cost effective & efficient
Excellent coupling with low leakage
meets human exposure limits to magnetic fields
Scalable for cars, trucks or buses
Ground clearance is vehicle dependent and varies
over time (suspension, loading etc.)
Horizontal tolerance allows unassisted parking
All Rights Reserved
Early 1kW UPF Charger
Battery Charger Pick-up
V
ac
Mains
I
ac
Mains
V
O
Load
I
O
Load
1kW (PF=0.998)
All Rights Reserved
Power Pad - Construction
420mm Diameter Power Pad
All Rights Reserved
2kW IPT Charger at EVS24
Charger: 2kW single phase supply
Pick-up: 2-5kW Power Pad
220mm airgap
Vehicle
controller
All Rights Reserved
Improving the Magnetic Design
All Rights Reserved
A New 3.5kW IPT Charger
Controlled Charging: 2kW from single phase supply
400mm
air-gap
Vehicle
controller
All Rights Reserved
2kW Charging
Pick-up: 2-5kW Power Pad
400mm airgap
Vehicle
controller
Exploring the freedom of
roadway power
All Rights Reserved
Brief Overview of Roadway IPT
1894 (Fr) Hutin & Le Blanc (proposed power to rail conductors)
1974 (NZ) Otto (series resonant system for buses)
1975 (US) Bolger (Inductive roadway switched loops)
1982-1992 (US) Santa Barbara project (Guided roadway)
1991 Lechner et.al. add improved magnetic design
1989-92 (US) Mushachio (proposes contact roadway)
1992 (US) Klontz (mining vehicles with coaxial clamp)
1994 (NZ) Boys and Green (bipolar track & multiple receivers)
1995 (JP) Sato (Meander tracks)
1997 (DE) Meins (early multiphase tracks)
2003 (NZ) Covic & Boys
(multiphase track & receivers - unguided roadway)
All Rights Reserved
1982 Santa Barbara Project
Pick-up 1m wide, 4.3m long (750Kg pickup & controller),
lowered to 3 inches height (7.5cm)
Capacitive compensation switched to regulate power and
variable tuning
All Rights Reserved
1992 - Klontz
Coaxial coupling for railed vehicles and EVs
2kHz, 500A track
Ideally 100kW transfer possible
All Rights Reserved
1994 Boys and Green
Disney project
Bipolar track
Multiple Pickups
Good tolerance
All Rights Reserved
1996 - Sato
Multiple primary coils or
meander configuration
Selectively excited
improved tolerance
Options for Single Phase
Tracks
All Rights Reserved
Single Phase Vehicle: Flat pick-ups
Traditional Single phase Flat Pick-ups
Flat-E Simple Flat
sc oc u
I V S =
0
2
4
6
8
10
-150 -100 -50 0 50 100 150
Distance from Track Centre (mm)
U
n
c
o
m
p
e
n
s
a
t
e
d

P
o
w
e
r

[
S
u
]
0
2
4
6
8
10
-150 -100 -50 0 50 100 150
Distance fromTrack Centre (mm)
U
n
c
o
m
p
e
n
s
a
t
e
d

P
o
w
e
r

[
S
u
]
All Rights Reserved
Commercial Flat-E Pick-ups
Continuous Power transfer
Um die Energiebertragung mglichst
effizient zu gestalten, d.h. arm an Um-
gebungsverlusten, empfehlen wir den
eingezeichneten Raum frei von ferro-
magnetischen Werkstoffen zu halten.
F-Abnehmer
Speiseleiter
(Hin- und Rc kleitung)
*
*
blicher Wert fr Einbaumittellage,
bitte spezifische Toleranzbereiche
der Abnehmer beachten !
Pickup Regulators
Pickups
All Rights Reserved
Existing AGVs and Robots
Precision alignment required for power transfer
0
1
2
3
4
5
6
-150 -100 -50 0 50 100 150
Distance fromTrack Centre (mm)
U
n
c
o
m
p
e
n
s
a
t
e
d

P
o
w
e
r

[
S
u
]
All Rights Reserved
Improving Lateral
Tolerance
All Rights Reserved
Quadrature Pick-ups
Uncompensated Power for Horizontal Coil
0
20
40
60
80
100
120
140
-150 -120 -90 -60 -30 0 30 60 90 120 150
Pickup Displacement (mm)
P
o
w
e
r

(
W
)
HORIZONTAL FLUX
Uncompensated Power for Vertical Coil
0
20
40
60
80
100
120
140
-150 -130 -110 -90 -70 -50 -30 -10 10 30 50 70 90 110 130 150
P
o
w
e
r

(
W
)
VERTICAL FLUX
VERTICAL FLUX
Multiphase (Quadrature) Pick-ups
All Rights Reserved
Adds significant lateral tolerance
(125A, 20kHz)
PICKUP
CONTROLLER
0
100
200
300
400
500
600
700
800
900
-150 -120 -90 -60 -30 0 30 60 90 120 150
P
o
w
e
r

(
W
)
Vertical Coil
Horizontal Coil
Vertical +
Horizontal
Specified Power
Specified Range
Quadrature Pick-ups
All Rights Reserved
Ferrite removed to accommodate the horizontal coil
Improved Quadrature Pick-ups:
Change Magnetic Shape
All Rights Reserved
Improved Quadrature pick-ups:
Added series compensation
L
2V C
2V
L
2H C
2PH
L
DC
S C
DC
R
L
C
2SH
Options with Multiphase Tracks
All Rights Reserved
Three Phase Control
3-phase
inverter
3-phase Isolating
Transformer & LCL
Network
Control
Circuit
Open-
Circuit
Protection
DC Input
Track
3-phase
inverter
LCL Network
DC Input
Control
Circuit
LCL Network
LCL Network
A+
C-
B+
A-
C+
B-
All Rights Reserved
Example toy systems
Multiphase tracks allow the freedom of a road lane
All Rights Reserved
3-phase tracks vs. Meander
Identical number track wires and current
80mm (3 phase) vs. 100mm separation meander
Both have 40A/phase
Three phase more than 3-4 times better (at centre)
Similar lateral tolerance
All Rights Reserved
Two Phase Tracks with Quadratrure
Power profiles using quadrature pickups
125A/phase, 20kHz
All Rights Reserved
Multiphase Tracks with Ferrite
5.0
5.5
6.0
6.5
7.0
7.5
8.0
8.5
9.0
9.5
2850 3350 3850 4350
P
s
u
(
k
V
A
)
Offset along track (mm)
0mm 100mm 200mm 300mm 400mm
240A/phase, 20kHz, 20cm height
A Possible Future
All Rights Reserved
The Vision
Power
Supply
cabinet
Vehicle lane
IPT Track
Power
Supply
cabinet
Vehicle lane
Power
Supply
cabinet
Power
Supply
cabinet
IPT Track IPT Track IPT Track
Pad
Pad Pad Pad
Pad Pad
Pad
Pad
Pad Pad Pad Pad
Pad
Pad Pad
Pad
200m
100m
All Rights Reserved
The Vision
All Rights Reserved
The Future
IPT applications are
limited only by our thinking
All Rights Reserved
Questions?

Covic IPT Powering Our Future PDF

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Inductive Power Transfer (IPT)

Powering our future

Contacts: j.boys@auckland.ac.nz or ga.covic@auckland.ac.nz

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