idaho national laboratory testing results: plugless ... · pluglesstm wireless charging system...
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Idaho National Laboratory
Testing Results: PLUGLESSTM Wireless
gov
Testing Results: PLUGLESS Wireless Charging System by Evatran Group Inc.
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Richard “Barney” Carlson October 2013
INL/CON-13-29978INL/CON-13-29978
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What is Wireless Charging for Plug-In Vehicles?What is Wireless Charging for Plug In Vehicles?• Wireless Power Transfer (WPT) across an air gap
– Power Electronics convert grid power (60Hz) to higher frequency power• Typical operating frequency: 20 kHz to 200 kHz• Typical operating frequency: 20 kHz to 200 kHz
– Coil to Coil coupling via magnetic resonance enables high efficiency power transfer across the air gap
– Higher frequency power rectified is into DC power to charge the batteryg q y p p g y
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INL Wireless Charging TestingINL Wireless Charging Testing• Scope: Provide Results from Testing
– System Efficiencyy y– Electric and Magnetic (EM) Field Strength– Impact on Grid (power quality, harmonics, etc.)
Support SAE J2954 committee– Support SAE J2954 committee
• Factors that impact System Efficiency and EM Field p y y– Coil to Coil Position
• Alignment (X, Y, , Tilt)Gap bet een coils• Gap between coils
– Output Power– Temperature (warm-up effects)
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p ( p )
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INL Wireless Charging Test EquipmentINL Wireless Charging Test Equipment• Programmable Loads
• AC Loads (9.0 kW) Chroma 63804• DC loads (58 kW) Chroma 63210
• Hioki 3390 Power Meter • 4 channel AC and DC current and voltage• 4 channel AC and DC current and voltage• Real-time integration for power & energy
• NARDA EHP-200a• Electric Field• Magnetic Field
• FLIR SC640 Thermal Camera• Fiberglass channel strut frame with multi-axis positioning table• CAN communications (as required)
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• CAN communications (as required)• Custom LabVIEW test control program for data acquisition and
test host function to synchronize all test operations
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INL Wireless Charging Laboratory TestingINL Wireless Charging Laboratory Testing
Fiberglass Channel Strut
Grid Power480 & 208 VAC Channel Strut
Supports Secondary Coil
Hioki Power
480 & 208 VAC
Narda EM Field Meter (EHP-200a)
Hioki Power Meter 3390
Polycarbonate Primary Coil
Stand-off
Multi-Axis Positioning
Chroma
ChromaAC Load
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SystemChromaDC Load Custom LabVIEW Host and
Data AcquisitionFLIR IR Camera
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INL Wireless Charger Coil PositioningINL Wireless Charger Coil Positioning• Primary Coil
– Software position controlB ll iti i• Ball-screw positioning table with servo motors
• X, Y, Supported by polycarbonate– Supported by polycarbonate stand-off
• Increase distance to the metallic positioning tableg
• Secondary Coil– Suspended from fiberglass
channel strut frameNon-Metallic Primary Coil
Support– Manually adjusted
• Z position (coil to coil Gap)• Tilt by differential Z
Suppo
Positioning
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Table
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PLUGLESSTM Wireless Charging System fromPLUGLESS Wireless Charging System from Evatran Group Inc.• Rated power: 3.3 kW output (208 VAC input as tested)• 30 A circuit breaker• 30 A circuit breaker• Nominal Gap between coils: 100mm (4.0”)• Vehicle application: Chevrolet Volt (as tested)• Dimensions:
– Primary Coil (circular) above ground installation• Approx. Circular: 559mm dia. x 470mm long
– Secondary Coil (oval) attaches under rear of vehicle• Rectangular: 464mm long x 525mm wide
http://www pluglesspower com/
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http://www.pluglesspower.com/wp-content/uploads/2013/06/PluglessL2_Specs.pdf
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INL Laboratory Test Setup: PLUGLESSTM by EvatranINL Laboratory Test Setup: PLUGLESS by Evatran• Three Measurement Nodes
– AC Grid Input (60 Hz)– Control Panel output to Primary Coil (parking pad)– Control Panel output to Primary Coil (parking pad)– DC Vehicle Adaptor output to On-Board Charge Module (OBCM)
– Secondary coil output was unable to be measured due to sealedSecondary coil output was unable to be measured due to sealed vehicle-side enclosure
DC
ACAC
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INL Laboratory Test Setupy p• Measurement orientation
– Origin: • Bottom face the Vehicle Adapter enclosure
z
Bottom face the Vehicle Adapter enclosure• Center of the Secondary Coil (inside Vehicle Adapter)
– X: towards front of vehicle– Y: towards drivers side x
y(i id d b SAE J2954)
– Z: up through roofZ
x (image provided by SAE J2954)
XY
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EM Field Frequency Scan 10kHz – 100kHzEM Field Frequency Scan 10kHz 100kHz• 100mm coil to coil gap, 3.3kW output power (nominal case)• EM field measurement position (baseline test position)
– X=0mm
z
X 0mm– Y=800mm (from the center of Secondary coil)– Z=-50mm (centered vertically in gap) x
y(image provided by SAE J2954)
• Operating frequency• 19.5 kHz
• Peak Magnetic Field (H-field)
• 12 9 A/m• 12.9 A/m • (16.2 T)
• Peak Electric Field (E field)
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(E-field)• 22.1 V/m
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Definition: System EfficiencyDefinition: System Efficiency
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System Efficiency Variation with Coil Positiony y• 3.3 kW output power• 100mm gap between coils• X-axis and Y-axis show Primary Coil
position relative to Secondary Coil
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EM Field Variation with Coil Position• 3.3 kW output power• 100mm gap between coils• X-axis and Y-axis show Primary Coil position relative to Secondary CoilX-axis and Y-axis show Primary Coil position relative to Secondary Coil
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Coil to Coil Gap Impact on System EfficiencyCoil to Coil Gap Impact on System Efficiency and EM Field• 3.3 kW output• EM field measured at• EM field measured at
– X=0.0m Y=0.8m – Centered vertically in gap (Z=-50mm)
Primary Coil position relative to Secondary Coil along Y-axis (mm)
14Primary Coil position relative to Secondary Coil along Y-axis (mm) Primary Coil position relative to Secondary Coil along Y-axis (mm)
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Output Power Impact on System Efficiency andOutput Power Impact on System Efficiency and EM Field• 100mm coil to coil gap• EM field measured at• EM field measured at
– X=0.0m Y=0.8m – Centered vertically in gap (Z=-50mm)
Primary Coil position relative to Secondary Coil along Y-axis (mm)
15Primary Coil position relative to Secondary Coil along Y-axis (mm)Primary Coil position relative to Secondary Coil along Y-axis (mm)
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Fact Sheet
16http://avt.inel.gov/evse.shtml
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Summary / Comments:Summary / Comments:• INL’s laboratory testing of the PLUGLESSTM Wireless Charging
system by Evatran Group Inc. is completeS t Effi i d EM fi ld t i t f– System Efficiency and EM field measurement impact from
• Coil to Coil Position– Gap– Alignment Offset
• Output Power• EM field meter measurement location
• Fact Sheet has been published– http://avt.inel.gov/evse.shtml
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AcknowledgementThis work is supported by the U.S. Department of
E ’ EERE V hi l T h l i P
Acknowledgement
Energy’s EERE Vehicle Technologies Program
More Informationhttp://avt.inl.gov