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ORNL Developments in
Stationary and Dynamic
Wireless Charging
Applications
Omer C. Onar
John M. Miller
Madhu Chinthavali
P.T. Jones
March 19, 2014
IEEE Applied Power Electronics Conference & Exposition (APEC)
Industry Session: Key Advances in Vehicle Power Electronics
2 Managed by UT-Battelle for the U.S. Department of Energy
Outline
• Introduction, Background, and Vision
• Power Electronics for Wireless Power Transfer Applications
• ORNL WPT Programs
– DOE FOA #667
– Laboratory Directed Research and Development on Dynamic WPT Demonstration
– WPT Development for Sustainable Campus Initiative
• SAE J2954 Standards Development Committee
– National Laboratory Role in Standards Development
– Test results and overview of ORNL 4-frequency band comparison study
3 Managed by UT-Battelle for the U.S. Department of Energy
Wireless Charging Projects at ORNL
• Provides convenience to the customer – No cord mess!
• Inherent electrical isolation.
• Minimum addition of hardware to the vehicle.
• Reduced on-board ESS size using dynamic on-road charging.
Vehicle Integration Components Development Test
2009-2010 open core WPT 2010-2012 magnetic resonant WPT
4 ORNL WPT Technology
ORNL’s Technology Development in WPT
Electromagnetics
& Coil Design
WPT Technology Evolution
Vehicle Integration
and
Communication
WPT Grid Side Regulation &
Front End Power Electronics
1 2
3 4
5 ORNL WPT Technology
Vehicle Implementations
6 ORNL WPT Technology
Power Electronics for WPT
7 ORNL WPT Technology
ORNL Grid-side Regulated WPT
• Wireless charging with grid side regulation moves the vehicle OBC function to the grid connection, much the same as DCFC with the addition of a coupler
WPT coil set
(Coupler)
8 ORNL WPT Technology
Active Front-End Rectifier with Power
Factor Correction
• Only left leg is utilized, right leg acts as diode phase-leg,
• Boost PFC circuit with more than 10 times boosting capability,
• Ideally run at 2-3 times boost factor,
• Can be interleaved for higher power rating,
• APT100MC120JCU2 SiC MOSFET is utilized for high efficiency, low loss, high switching frequency for reduced current ripples.
9 ORNL WPT Technology
• 2-switch boost type PFC experimental results at 7.7 kW
– Input 220Vac; Output: 590 Vdc at 4.65 kW; included in Demo #1
– Input line current 36 Arms (7.92 kVA); PF~0.99, eff: 96.5% to 97.4%, THD<5%
Capacitors– AVX 800V film main dc link ripple control
HF power inverter snubbers are Kemet 1,000V film
Issue: Dc link high voltage, high ripple current rated, film capacitor
Line Volts: 500 V/div
Line Amps: 50 A/div
Output Volts: 500 V/div
Output Amps: 20 A/div
Active Front-End Rectifier with Power
Factor Correction
10 ORNL WPT Technology
High Frequency Power Inverter
• International Rectifier non-commercial devices have been tested and utilized in some of the tests and developments,
• Currently using 600V, 600A Powerex Intellimod IGBT phase-leg modules with integrated gate drive circuits and utilized protection schemes such as overvoltage, overcurrent, short circuit, and over-temperature protections,
• Also built high frequency wide bandgap inverters using in-house made/packaged SiC MOSFETs and commercial SiC MOSFETs for the ORNLs four-frequency band comparisons test study.
Si IGBT based Inverters SiC MOSFET based Inverters
11 ORNL WPT Technology
FOA #667 Phase I – Stationary WPT
Development
12 ORNL WPT Technology
DOE Wireless Charging FOA
• A multi-party team to develop 10 kW capable wireless power transfer (WPT) apparatus, and demonstrate on retrofitted GM and Toyota vehicles at full power matching J1772 standard conductive charging efficiency of >85%.
Overall program
• ORNL is program lead and
demonstration site #1
• GM and Toyota Motor Corp.
provide vehicles
• CU-ICAR for communications
and demonstration site #2
• Evatran is commercialization
partner and vehicle integrator
ORNL’s technology meets international
standards on high frequency electromagnetic
fields.
Project drives standardization with SAE J2954
WPT Task Force for 2015 guideline
Field Demo/ V2I
(Commercialization Partner)
YEAR
3
YEAR
2
YEAR
1
Core High
Power WPT
Research
13 ORNL WPT Technology
Control System – HF Inverter
• Stationary Wireless Charging
– ORNL 10 kW WPT demonstration part of DOE DE-FOA-0000667 Oct. 2012
– Develop deep knowledge in coupling coil design essentials, power flow regulation, leakage field minimization, misalignment tolerance, plus
– Work closely with SAE J2954 Wireless Charging Task Force on interoperability
𝑈𝑑𝑜 = 𝜋
2 2 𝑈𝑠 + 𝑟𝑝 𝑖𝑝 + 𝑈𝑠𝑤
𝑃𝐹 = cos arg 𝑈𝑠 − arg(𝑖𝑝)
acU Front End
Grid Interface
Converter
1T
2T 4T
+
-
doU
1G
2G
3G
4G
sU
1C
1L 2L
M
2CoC
oU
1I 2I+
-
bUbI3T
doI
2D
1D 3D
4D
HF Inverter
Primary and
Secondary Coils
Bridge Rectifier &
Filter
𝑈𝑠 𝑡 =4𝑈𝑑𝑜
𝜋sin 𝑑
𝜋
2 cos 𝜔𝑡 (𝑉𝑟𝑚𝑠 )
14 ORNL WPT Technology
WPT System Complete Control Loop
WPT system block diagram with active front end rectifier with power factor correction
Pbatt_ref
Π
Vbatt
Ibatt_ref
×÷
Σ+
-
Ibatt
s
KsK IP 11
PI Controllerε Igrid_ref
(magnitude)
Vac Vgrid
PLL
ψ(Grid voltage
phase)
Waveform
Generator
Igrid_ref
(waveform)
Switching
States
Igrid
(sensed)G1 to G4
s
KsK IP 22 Σ
PI Controllerε
WPT complete control system loop for tracking the reference charging power to the vehicle battery by controlling the DC link voltage to the inverter input through the AFE with PFC
15 ORNL WPT Technology
Fabricating Coupling Coils
• ORNL WPT coil development: (a) Soft Ferroxcube 3C94 ferrite coils placed on aluminum shielding case and ferrites covered by non-conductive material before winding, (b) Litz wires being winded on ferrite cores, (c) winding of Litz wires completed and transmit coil enclosed in a Lexan box, (d) sealed receive coil to be mounted underneath the vehicle.
• The coils are tuned to f01=22kHz with L1=L2=122.21mH, C1=C2=0.44mF and f02=21.29kHz, R1dc=R1dc=64.45mW. The variation of coupling coefficient with coil spacing, k(z), is of essence to characterize the coils and tune the coils.
(a) (b)
(c) (d)
16 ORNL WPT Technology
Coil Characterization - Coupling Coefficient
• In laboratory tests performed at ORNL an Industrial Electronics model 1500A Powertron amplifier and signal generator are used to apply current to the primary coil of the coupling coil pair.
• Coupling coefficient by open circuit characterization:
• Inductance aiding method:
• k-compensation method:
zgapAI
UUoc
rms
OCU
Uzk
101
2
1
2
)(
z
aidaid
LL
LLLzk
21
21
2
)()(
10)(
1
2
oc
scoccomp
U
IUzk
60 80 100 120 140 160 180 2000.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
k-Open Circuitk L-aidingk-comp
Distance between coils, z [mm]
Coupli
ng c
oeff
icie
nt,
k
17 ORNL WPT Technology
Stationary Wireless Charging
• ORNL control method and power flow regulation experience – WPT architecture is HF transformer isolated, Series/Parallel tuned, direct to HV battery
– Power flow is function of gap, misalignment, and battery SOC: P(z, Ubat)
– Increasing gap (125mm < z < 200mm) requires down shift in frequency, fs.
– Increasing battery voltage (20% < SOC < 95%) requires increase in HF stage rail voltage via PFC to maintain constant power
Frequency tracks gap variation
20 21 22 23 24 25 260
1000
2000
3000
4000
5000
6000
7000
8000
9000
Iput DC powerOutput DC power
Frequency [kHz]
Inp
ut
and
Ou
tpu
t D
C P
ow
ers
[W]
2000
2500
3000
3500
4000
4500
5000
5500
6000
6500
Po
wer
[W
]
Frequency [kHz]
Primary P [W] 150mm gap
Secondary P [W] 150mm gap
Primary P [W] 125mm gap
Secondary P [W]125mm gap
Primary P [W] 175mm gap
Secondary P [W] 175mm gap
18 ORNL WPT Technology
Entire System Integration for Test
Bench Demo
• SiC Active Front-end Rectifier (AFER) with power factor correction (PFC)
• PFC converter control system
Pbatt_ref
Π
Vbatt
Ibatt_ref
×÷
Σ+
-
Ibatt
s
KsK IP 11
PI Controllerε Igrid_ref
(magnitude)
Vac Vgrid
PLL
ψ(Grid voltage
phase)
Waveform
Generator
Igrid_ref
(waveform)
Switching
States
Igrid
(sensed)G1 and G2
s
KsK IP 22 Σ
PI Controllerε
SGN
• Primary and secondary coils
• Tuning capacitors and HF transformer
• Integrated PFC and HF power inverter
19 ORNL WPT Technology
Entire System Integration for Test
Bench Demo
• Test results @137mm airgap at 6.6kW
• Test results @160mm airgap at 6.6kW
20 ORNL WPT Technology
Entire System Integration for Test
Bench Demo
• Test results @160mm airgap at 10.2kW (without PFC stage, direct DC to inverter input) • At 10.2 kW to the
battery load:
– Magnetic Field: 0.5847 uT – highest peak
– Electric Field: 3.52 V/m – highest peak
21 ORNL WPT Technology
LDRD WPT Program – In-motion WPT
Demonstration
22 ORNL WPT Technology
In-motion Wireless Charging
Demonstration
• World’s very first in-motion wireless charging system using coils (not using rails or long wire loops as in previous technologies)
• Dynamic Wireless Power Transfer (WPT)
– ORNL demonstration: GEM EV and 6-coil track
– Also addressed motion dependent power pulsations
• Achieved 3 industry firsts: 1) in-vehicle charge power smoothing using carbon ultracapacitors, 2) grid side power smoothing using lithium-capacitors (LiC), 3) both in combination
23 ORNL WPT Technology
ORNL Dynamic WPT Demonstrator
• DWPT Experimental Results • GEM vehicle driving across roadway
coils
2.5 3 3.5 4 4.5 5 5.5 6 6.5 7 7.5130
135
140
145
150
155
160
165
170
Time [s]
Li-
Ion C
apac
itor
Volt
age
[V]
Powering first
coil pair
Powering second
coil pairPowering third
coil pair
Inverter OFF
time
Inverter OFF
time
Vehicle stays on
top of the last coil
Inverter OFF
time
2 3 4 5 6 7 8-10
0
10
20
30
40
50
Time [s]
Li-
ion C
apac
itor
Curr
ent
[A]
Inverter OFF
time
Powering first
coil pair
Powering second
coil pair
Powering third
coil pair
Inverter OFF
time Inverter OFF
time
Vehicle stays on
top of the last coil
24 ORNL WPT Technology
ORNL Dynamic WPT Demonstrator
• Feedback from electrified roadway optical sensors are utilized to turn the inverter ON and OFF depending on the vehicle tire positions.
• Contactors are also controlled to direct the power from the inverter to the particular set of coils.
Powering first coil pair
3.965 3.97 3.975 3.98 3.985 3.99 3.995-5
0
5
10
15
20
25
30
35
40
Time [s]
Li-
ion
Cap
acit
or
Cu
rren
t [A
]
Powering second coil pair
Inverter turn-OFF time
25 ORNL WPT Technology
ORNL Dynamic WPT Demonstrator
• Primary coil current due to inverter turn OFF and ON and coil sequencing
Powering first
coil pair
2 3 4 5 6 7 8-250
-200
-150
-100
-50
0
50
100
150
200
250
Time [s]
Pri
mar
y C
oil
Cu
rren
t R
ou
ted
by
Co
nta
cto
rs [
A]
Powering second
coil pair
Powering third
coil pair
Vehicle stays on
top of the last coil
Powering first
coil pair
3.8 3.85 3.9 3.95 4 4.05 4.1 4.15 4.2-250
-200
-150
-100
-50
0
50
100
150
200
250
Time [s]
Pri
mar
y C
oil
Curr
ent
Route
d b
y C
onta
ctors
[A
]
Powering second
coil pair
Inverter turn-OFF
time
Inverter turn-OFF transition
and coil current fall
3.967 3.9675 3.968 3.9685 3.969 3.9695 3.97-250
-200
-150
-100
-50
0
50
100
150
200
250
Time [s]
Pri
mar
y C
oil
Curr
ent
Route
d b
y C
onta
ctors
[A
]
Inverter turn-ON transition
and coil current rise
3.993 3.9932 3.9934 3.9936 3.9938 3.994 3.9942 3.9944 3.9946 3.9948 3.995-250
-200
-150
-100
-50
0
50
100
150
200
250
Time [s]
Pri
mar
y C
oil
Curr
ent
Route
d b
y C
onta
ctors
[A
]
Illustration of roadway coil current quenching (0.2ms) and inverter turn-ON coil current ring-up (1.4ms)
26 ORNL WPT Technology
ORNL Developments in WPT Charging
• Dynamic WPT
• Demonstrated in-motion wireless charging of GEM EV, Sept 2013
• Achieved 3 industry firsts: 1) in-vehicle charge power smoothing using carbon ultracapacitors, 2) grid side power smoothing using lithium-capacitors (LiC), 3) both in combination
• Effectively reduced vehicle battery and grid side power ripples.
Grid side LiC
Vehicle side carbon UC
LiC
ra
ck fa
bricate
d b
y E
lectr
o S
tand
ard
s
La
bo
rato
ries, C
ran
sto
n, R
I. D
r. R
ay S
ep
e
27 ORNL WPT Technology
ORNL Dynamic WPT Demonstrator
• Current ripple smoothing with Li-ion capacitors on the grid side unit and carbon electrochemical ultra-capacitors on the vehicle side.
28 ORNL WPT Technology
ORNL Dynamic WPT Demonstrator
• Current ripple smoothing with Li-ion capacitors on the grid side unit and carbon electrochemical ultra-capacitors on the vehicle side.
Current ratio (Ipk/Iavg) Grid-side WPT base station In-vehicle
No smoothing 53A 16A
Grid-side only with LiC 10A 16A
Vehicle side with UC 10A 2.6
Vehicle side with LiC 10A 2.6
Pulse reduction 81% 84% for UC
84% for LiC
29 ORNL WPT Technology
ORNL WPT Development for the
Sustainable Campus Initiative
30 ORNL WPT Technology
Stationary Wireless Charging
• Integrating WPT into a PRIUS PHEV demo vehicle
– Vehicle chassis construction and ground clearance requirements resulted in placement of the environmentally sealed secondary coil beneath the trunk
– Secondary HF cable routed directly into cargo space alongside L5 auxiliary battery pack (5 kWh Li-ion)
– Secondary electronics, contactor, CAN and HMI, radio all in one box
31 ORNL WPT Technology
Stationary Wireless Charging
• HMI installation into a PRIUS PHEV demo vehicle
– Vehicle CAN accessed and battery status and related information provided to in-cabin display
32 ORNL WPT Technology
Peripherals & Radio communications
• Communications o Initial tests using B&B Electronics Zlinx radio modem @ 2.4 GHz
VWPT – vehicle side WPT
Zlinx wireless modem
Woodward GCM-0563-048,
CAN capable
Woodward GCM-0563-048
Freescale MPC563 @ 56 MHz
32k RAM, 64k EEPROM
8-32Vdc, -40C<Top<+85C
11-18 analog input
Spectrum Digital E2DSP using
TI-TMS320F28335 core
32bit, 150 MHz, 68k RAM, 256k SRAM
RS232, CAN 2.0, 12bit ADC
Validation tested at ORNL
• Messages of 6 bytes
• Round trip time of ~20 ms
• WPT will require 8 bytes
• Proved interoperable
Grid-side power controller and communications Vehicle side communications
33 ORNL WPT Technology
Conclusions
• ORNL managed 3 programs in wireless charging during FY13
– Internal funded dynamic wireless charging of GEM EV
– Internal funded stationary wireless charging of PRIUS Hymotion mail delivery vehicle, including full charging site integration
– DOE funded high power stationary charging vehicle demonstration
• Data sharing with partners, other national laboratories, IEEE-SA, and with SAE J2954 wireless charging task force
• ORNL WPT systems development guided by focus on health and safety
– Coupling coils that focus the magnetic field complimented by shielding of leakage fields
– HF isolation transformer for galvanic isolation of primary pad
– Advanced techniques for object/pet detection in between coils, misalignment detection/compensation for better coupling
• ORNL is committed to WPT knowledge generation for societal benefit
– Participating in standards committee for WPT guidelines
– Collaborating with other WPT manufacturers on FCC notice of proposed rule making that would include wireless vehicle charging
– Publication of results in technical papers, tutorials, and articles
34 ORNL WPT Technology
Questions & Discussions
• Contact Information
– Omer C. Onar, [email protected], 865-946-1351
– PT Jones, [email protected], 865-946-1472
– Madhu Chinthavali, [email protected], 865-946-1411