Design optimization of contactless power transfer systems for electric vehicles using electromagnetic resonant coupling

Contactless power transfer (CPT) systems have been gaining considerable attention and have achieved tremendous technology advancements across a wide variety of utilizations in the past decade. CPT technologies offer promising advantages and open up new avenues for development of numerous real-world applications. Of particular importance is the implementation of CPT systems on the charging of electric vehicles (EV), which are considered as a sustainable alternative that will effectively address global fossil energy scarcity and climate change issues in the future. The overarching aim of this thesis is to investigate and improve the operation performance of CPT systems for contactless EV charging. Optimized high-performance CPT systems are expected to be the ultimate goal for EV wireless charging in the following century. In the CPT applications, some certain characteristic outputs and parameters such as overall system efficiency, RMS power transfer, air gap and resonant frequency are considered as key performance metrics to be addressed. These crucial metrics and properties have been emphasized throughout this thesis. The electromagnetic resonant coupling technique has been put forward and adopted for most designed prototypes in this thesis in order to optimize the overall performance of CPT systems. The research methodology development, model designs, implementations and results analysis of the thesis are undertaken from the perspective of both power electronics and electromagnetics towards achieving the main objectives of the research. With focuses on overall system efficiency, real transfer power to load, air gap, frequency, magnetic coupler design, shielding materials, inner shielding distance and misalignment characteristics, a range of studies have been conducted in the thesis based on the proposed methodology, enhanced simulation models and laboratory prototypes. A number of important contributions have been made by the thesis. The four most significant contributions are: Firstly, the originally developed methodology for the CPT research of the thesis – the research flowchart system based on the preliminary natural resonant frequency probe and anticipation method. This uniquely proposed method for this thesis has been used to effectively probe, track and narrow down the most appropriate resonant frequency range to be chosen for CPT systems to perform with, towards reaching an optimized status of electromagnetic resonant coupling in terms of CPT technology-based EV charging. Secondly, the magnetic coupler modular-based CPT designs for investigating overall system performance optimization. As a result, in the thesis, a novel small-sized CPT prototype that is based on a geometrically improved H-shaped magnetic coupler, with ferromagnetic cores, passive aluminium shielding, an SS compensation topology and electromagnetic resonant coupling, has been proposed as an optimal design solution. Thirdly, approximating a CPT system to operate in close proximity to its calculated natural resonant frequency point by tuning and controlling system operating frequency could effectively lead to an overall system performance optimization most of the time in practical applications using electromagnetic resonant coupling, whereas setting the system operating frequency exactly at its calculated natural resonant frequency to make the system maximally operate at an extreme state of magnetic resonance may only produce a partial optimization from perspective of the system parameters and outputs. Fourthly, reasonable trade-offs between performance metrics are required to be considered and evaluated in order to achieve a feasible overall CPT system optimization. Through the detailed analysis of the results, model outcome comparisons, explanations on findings, limitation discussions and holistic system evaluations, this thesis is devoted to report and provide a series of newly proposed solutions and innovatively designed CPT systems. These solutions are supported by empirical findings, conclusions and contributions, which may encourage further pursuits of system performance optimizations for high-power high-frequency CPT charging technologies applied for future EV, despite methodological limitations, experiment restrictions and external uncertainties.