This paper reviews the current status and implementation of battery chargers, charging power levels, and infrastructure for plug-in electric vehicles and hybrids. Charger systems are categorized into off-board and on-board types with unidirectional or bidirectional power flow. Unidirectional charging limits hardware requirements and simplifies interconnection issues. Bidirectional charging supports battery energy injection back to the grid. Typical on-board chargers restrict power because of weight, space, and cost constraints. They can be integrated with the electric drive to avoid these problems. The availability of charging infrastructure reduces on-board energy storage requirements and costs. On-board charger systems can be conductive or inductive. An off-board charger can be designed for high charging rates and is less constrained by size and weight. Level 1 (convenience), Level 2 (primary), and Level 3 (fast) power levels are discussed. Future aspects such as roadbed charging are presented. Various power level chargers and infrastructure configurations are presented, compared, and evaluated based on amount of power, charging time and location, cost, equipment, and other factors.

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Review of Battery Charger Topologies, Charging Power Levels, and Infrastructure for Plug-In Electric and Hybrid Vehicles

Wireless power transfer (WPT) using magnetic resonance is the technology which could set human free from the annoying wires. In fact, the WPT adopts the same basic theory which has already been developed for at least 30 years with the term inductive power transfer. WPT technology is developing rapidly in recent years. At kilowatts power level, the transfer distance increases from several millimeters to several hundred millimeters with a grid to load efficiency above 90%. The advances make the WPT very attractive to the electric vehicle (EV) charging applications in both stationary and dynamic charging scenarios. This paper reviewed the technologies in the WPT area applicable to EV wireless charging. By introducing WPT in EVs, the obstacles of charging time, range, and cost can be easily mitigated. Battery technology is no longer relevant in the mass market penetration of EVs. It is hoped that researchers could be encouraged by the state-of-the-art achievements, and push forward the further development of WPT as well as the expansion of EV.

Wireless Power Transfer for Electric Vehicle Applications

This paper overviews theoretical and practical design issues related to inductive power transfer systems and verifies the developed theory using a practical electric vehicle battery charger. The design focuses on the necessary approaches to ensure power transfer over the complete operating range of the system. As such, a new approach to the design of the primary resonant circuit is proposed, whereby deviations from design expectations due to phase or frequency shift are minimized. Of particular interest are systems that are neither loosely nor tightly coupled. The developed solution depends on the selected primary and secondary resonant topologies, the magnetic coupling coefficient, and the secondary quality factor.

Design considerations for a contactless electric vehicle battery charger

Inductive power transfer is a practical method for recharging electric vehicles because it is safe, convenient, and reliable. The performance of the magnetic couplers that transfer power determines the overall feasibility of a complete system. Circular couplers are the most common topology in the literature; however, they have fundamentally limited coupling. Their flux patterns necessarily limit the operational air gap as well as tolerance to horizontal misalignment. A new polarized coupler topology [referred to as a double D (DD)] is presented, which overcomes these difficulties. DDs provide a charge zone five times larger than that possible with circular pads for a similar material cost and are smaller. A 0.31-m2 DD enables 2 kW of power transfer over an oval area measuring 540 mm × 800 mm with a 200-mm air gap. Leakage magnetic fields have been investigated and show that circular and DD couplers operating under similar power transfer conditions produce similar levels. Both topologies can be designed and operated to ensure compliance with international guidelines.

Development of a Single-Sided Flux Magnetic Coupler for Electric Vehicle IPT Charging Systems

Inductive power transfer (IPT) has progressed to be a power distribution system offering significant benefits in modern automation systems and particularly so in stringent environments. Here, the same technology may be used in very dirty environments and in a clean room manufacture. This paper reviews the development of simple factory automation (FA) IPT systems for both today's complex applications and onward to a much more challenging application-IPT roadway. The underpinning of all IPT technology is two strongly coupled coils operating at resonance to transfer power efficiently. Over time the air-gap, efficiency, coupling factor, and power transfer capability have significantly improved. New magnetic concepts are introduced to allow misalignment, enabling IPT systems to migrate from overhead monorails to the floor. However, the demands of IPT roadway bring about significant challenges. Here, compared with the best FA practice, air-gaps need to be 100 times larger, power levels greater than ten times, system losses ten times lower to meet efficiency requirements, and systems from different manufacturers must be interoperable over the full range of operation. This paper describes how roadway challenges are being met and outlines the problems that still exist and the solutions designers are finding to them.

Modern Trends in Inductive Power Transfer for Transportation Applications

Loosely coupled inductive power transfer (LCIPT) systems are designed to deliver power efficiently from a stationary primary source to one or more movable secondary loads over relatively large air gaps via magnetic coupling. In this paper, a general approach is presented to identify the power transfer capability and bifurcation phenomena (multiple operating modes) for such systems. This is achieved using a high order mathematical model consisting of both primary and secondary resonant circuits. The primary compensation is deliberately designed to make the primary zero phase angle frequency equal the secondary resonant frequency to achieve maximum power with minimum VA rating of the supply. A contactless electric vehicle battery charger was used to validate the theory by comparing the measured and calculated operational frequency and power transfer. For bifurcation-free operation, the power transfer capability and controllability are assured by following the proposed bifurcation criteria. Where controllable operation within the bifurcation region is achievable, a significant increase in power is possible.

Power transfer capability and bifurcation phenomena of loosely coupled inductive power transfer systems

A inductor/capacitor/inductor load resonant inverter is investigated for inductive power transfer applications. The inverter uses a variable frequency controller and operates in discontinuous current mode. The steady state operation of this system is determined by a power flow balance between the inverter and the resonant tank. The results are used to design a system to achieve maximum power transfer.

Investigating an LCL load resonant inverter for inductive power transfer applications

Load models are developed as a design tool for loosely coupled inductive power transfer systems. The models are used to investigate the sensitivity of these systems to variations in operational frequency and load. The results of the investigation can then be used to determine the power transfer capability and controllability of the system.

Load models and their application in the design of loosely coupled inductive power transfer systems

Loosely coupled inductive power transfer (LCIPT) systems are designed to deliver power efficiently from a stationary primary source to one or more movable secondary loads over relatively large air-gaps, however this becomes more difficult as the complexity of the system grows. A general analysis of such LCIPT systems is essential for optimal system design. This analysis is undertaken for LCIPT systems that attempt to operate with zero phase angles between the primary input voltage and current in order to achieve minimum cost and maximum performance. The paper develops general boundary conditions that if followed ensures only one operating condition exists for any practical load thereby assuring stable operation and power transfer capability. This is verified by measuring a contact-less electric vehicle battery charging system.

Chwei-Sen Wang

Papers

Design considerations for a contactless electric vehicle battery charger

Power transfer capability and bifurcation phenomena of loosely coupled inductive power transfer systems

Investigating an LCL load resonant inverter for inductive power transfer applications

Load models and their application in the design of loosely coupled inductive power transfer systems

General stability criterions for zero phase angle controlled loosely coupled inductive power transfer systems