EV Fig.. Contactless power transfer system. (a) Single-sided winding transformer. Fig. 2. Detailed equivalent circuit. x 0, x, x 2 r 0 r, r 2 C P R L

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D IEEJ Transactions on Industry Applications Vol.32 No. pp.9 6 DOI: 0.54/ieejias.32.9 Novel Core Structure and Iron-loss Modeling for Contactless Power Transfer System of Electric Vehicle Masato Chigira, Student Member, Yuichi Nagatsuka, Non-member, Yasuyoshi Kaneko,Member, Shigeru Abe, Member, Tomio Yasuda, Member, Akira Suzuki, Non-member 20 3 25 20 0 3 A contactless power transfer system for electric vehicles needs to have a high efficiency, a large air gap, good tolerance to misalignment in the lateral direction and be compact and lightweight. In this paper, a new.5 kw transformer has been developed using novel H-shaped core which is more efficient, more robust to misalignment and lighter than previous rectangular core to satisfy these criteria, and its characteristics are described. An efficiency of 95% was achieved across 70 mm mechanical gap. The modeling of iron-loss in the equivalent circuit is also presented. The calculated efficiency using this model shows good agreement with experimental results. Keywords: electric vehicle, contactless power transfer system, efficiency, core, temperature rise test, iron-loss. () (3) (4) (8) Auckland Boys 2009 (3) 200 Flux pipe (9) (0) 338-8570 255 Saitama University 255, Shimo-Okubo, Sakura-ku, Saitama 338-8570, Japan 00-00 -- Technova Inc. --, Uchisaiwai-cho, Chiyoda-ku, Tokyo 00-00, Japan 444-92 0 AISIN AW CO., LTD. 0, Takane, Fujii-cho, Anjo 444-92, Japan H.5 kw 240 300 40 mm 3.9 kg 70 mm ±50 mm 94% k r 0 r 0 r 0 2. 2 () Fig. 2 2 C S, C P R L Fig. 2 a = N /N 2 r 0 r, r 2 > 0 khz c 202 The Institute of Electrical Engineers of Japan. 9

EV Fig.. Contactless power transfer system. (a) Single-sided winding transformer. Fig. 2. Detailed equivalent circuit. x 0, x, x 2 r 0 r, r 2 C P R L 2 3 C P f 0 (= ω 0 /2π) x 0 x 2 ω 0 L 2 () ω 0 C P = x p = x 0 + x 2 = ω 0 L 2 () C S (2) ω 0 C S = x s = x 0 x 2 x 0 + x + x (2) 2 2 4 (2) () (2) C S C P () (2) V IN V 2 I IN I D V IN = bv 2, I IN = I D/b, b = x 0 + x (3) 2 b (2) (3) 2 5 x 0 Fig. 2 r 0 (3) η (4) η max R Lmax (5) (4) (5) R L IL 2 η = R L IL 2 + r I2 IN + = r 2 I2 2 R L + r b + r 2 2 R L + ( RL x P ) 2 (4) Fig. 3. η max = (b) Double-sided winding transformer. Single and double-sided winding transformers. + 2r 2 x P 2 6 r, R Lmax = x P + r b 2 r 2 + b 2 r 2 (5) () (3) (4) (8) k k 2 40% (3) Fig. 3(a) (A) (B) (A) (B) k 4 y (A) (B) k 0 IEEJ Trans. IA, Vol.32, No., 202

EV 3. H 3 H Fig. 4(a) (5) Fig. 4 x k Fig. 4(b) H H () (2) (3) (4) H Table x y H Table 2 Fig. 4 Table 2 H 3.9 kg 4.6 kg 2.9 kg 2.0 kg 70 mm ±30 mm x ±45 mm y ±50 mm H (a) Transformer with rectangular core. (b) Transformer with H-shaped core. Fig. 4. Transformer s photographs and their dimensions. Table. Design goal. Table 2. Specification. IEEJ Trans. IA, Vol.32, No., 202

EV H 5mm H 70 mm 60 mm R L LCR C S C P H () (2) Fig. 400 mm 600 mm mm 3 2 70 mm Table 3. Parameters of standard position (gap = 70 mm). Table 3 H k η max H r 2 f 0 x 0 (= 2π f 0 l 0 ) Table 4 Fig. 5 η (= P 2 /P ) 70 mm 95.3% 94.6% H 94.9% Fig. 5 H V IN I IN V 2 V IN I IN I 2 L 2 C P 3 3 H Fig. 6 x y Fig. 4 l 0 k L 2 C P () C S C P R L Fig. 2 V 2 V L Table 4. Experimental results (gap = 70 mm). Fig. 5. Wave forms of transformer with H-shaped core. (a) With change in gap length. Fig. 6. (b) With change in positions. Experimental results for transformer with H-shaped core. 2 IEEJ Trans. IA, Vol.32, No., 202

EV Fig. 7. Characteristics with resistance-load change. Fig. 8. Temperature rise test. V L /V 2 80 Ω k b (3) V 2 /V IN P OUT =.5 kw V IN V IN V 2 (3) η 40 mm 70 mm 00 mm 95.2% 94.9% 93.% 3 4 70 mm x 45 mm y 50 mm Table 4 Fig. 6(b) V 2 /V IN y η 93.% H 93.0% y 2.2% H.9% H y 94% H y 0.2 T 0.22 T 0.5 T.5 kw 3 5 70 mm x = y = 0 V L R L 60 240 Ω Fig. 7 Fig. 7 (4) R L V L /V 2 (6) η V IN V 2 V 2 /V IN 4. H 4 70 mm 40 mm 40 mm 00 mm 00 mm C S C P () (2) 00 mm P OUT =.5 kw V IN 00 mm k 0.24 b 0.24 70 mm V IN η Fig. 6(a) 70 mm 00 mm 30 mm 93.5% 92.% 89.7% ±30 mm 9.9% 70 mm 94.5% 2.5% B 2 0.24 T 0.5 T 00 mm ± 30 mm.5 kw 4 2 H AC00 V.5 kw 4 0 H Fig. 8 3 20 C 60 C 8 η.0% 4 3 3kW AC00 V AC200 V H 3kW 70 mm x = y = 0 Table 4 η 94.7% B 2 0.29 T 3kW 3 IEEJ Trans. IA, Vol.32, No., 202

EV.5 kw R L = 80 Ω.5 kw H 3kW 5. 2 5 (4) r 0 k r 0 r 0 5 V, V 2 V, V 2 V, V 2 (3) b V, V 2 R L r 0 Fig.9 5 r 0 Fig. 9(a) V 2 V 20 V IN (6) P A V = V I IN V V V 0 P C (V ) V P C2 (V 20 ) V 20 P A = P C (V ) + P C2 (V 20 ) = P r IIN 2 r 2I2 2 (6) 2 Fig. 9(b) V = V (< V 0 ) V IN (7) P B V 2 V 20 P C (V 0 ) + P C2 (V 20 ) = P A + P C P B = P D (9) 5 r 0 R L Fig. 2 I 0 (0) r 0 r 0 = P D = P C (V 0 ) + P C2 (V 20 ) (0) I0 2 I0 2 H.5 kw 3kW Table 5 Table 5 V 2, V 22 V 20 (9) P C P A P B r 0 Table 6 H.5 kw 3kW Table 5 P D Table 6 Other loss 5 2 Fig. 2 r 0 2 5 η R L η max () (2) (3) R L IL 2 η = R L IL 2 + r I 2 IN + r 2I2 2 + r 0 I 2 0 = R L + r b +r 2 2 + ( RL x P R L ) 2 +r 0 ( b) 2 b 2 + ( RL x P ) 2 () r R Lmax = x + r 2 + r 0 ( b)2 P b 2 r 2 + r 0 (2) η max = + 2r 2 + r 0 r + r 2 + r 0 ( b)2 x P b 2 r 2 + r 0 (3) Fig. 7 (4) () P B = P C (V ) + P C2 (V 2 ) = P r IIN 2 (7) 3 Fig. 9(b) V V 0 V IN (8) P C V 22 V 20 Table 5. No-load test results. P C = P C (V 0 ) + P C2 (V 22 ) = P r I 2 IN (8) 4 P C2 (V 2 ) P C2 (V 22 ) 0 Table 6. Breakdown of transformer loss. (a) With resonant capacitors. (b) Without resonant capacitors. Fig. 9. Circuit for no-load test. 4 IEEJ Trans. IA, Vol.32, No., 202

EV Fig. 0. Efficiency as a function of resistance load. Fig. 0.5 LCR 6. H.5 kw 70 mm H 240 300 40 mm 3.9 kg ±50 mm 94% r 0 r 0 C.-S. Wang, O.H. Stielau, and G.A. Covic: Design consideration for a contactless electric vehicle battery charger, IEEE Trans. Ind. Electronics, Vol.52, No.5, pp.308 34 (2005) 2 Y. Kamiya, Y. Daisho, and H. Matsuki: Inductive Power Supply System for Electric-driven Vehicles, IEEJ Journal, Vol.28, No.2, pp.804 807 (2008) (in Japanese),, Vol.28, No.2, pp.804 807 (2008) 3 M. Budhia, G.A. Covic, and J.T. Boys: Design and Optimisation of Magnetic Structures for Lumped Inductive Power Transfer Systems, IEEE ECCE, pp.208 2088 (2009) 4 T. Iwata, N. Ehara, Y. Kaneko, S. Abe, T. Yasuda, and Ida: Comparison of characteristic by Transformer Winding Method of Contactless Power Transfer Systems for Electric Vehicle, The Paper of Technical Meeting on Semiconductor Power Converter (SPC), IEE Japan, SPC-09-39, pp.09 4 (2009) (in Japanese),, SPC-09-39, pp.09 4 (2009) 5 N. Ehara, Y. Nagatsuka, Y. Kaneko, S. Abe, T. Yasuda, and K. Ida: Compact and Rectangular Transformer of Contactless Power Transfer System for Electric Vehicle, Proc. of 2009 Japan Industry Applications Society Conference, IEE Japan, No.2-25 (2009) (in Japanese), 2, No.2-25 (2009) 6 S. Noguchi, Y. Nagatsuka, Y. Kaneko, S. Abe, T. Yasuda, and A. Suzuki: Compact and Rectangular Transformer of Contactless Power Transfer System for ElectricVehicle, Proc. of 200 Japan Industry Applications Society Conference IEE Japan, No.2-6, pp.ii-259-262 (200) (in Japanese), 22, No.2-6, pp.ii-259 262 (200) 7 Y. Nagatsuka, N. Ehara, Y. Kaneko, S. Abe, and T. Yasuda: Compact Contactless Power Transfer System for Electric Vehicles, Proc. of 200 International Power Electronics Conference (IPEC200-Sapporo), IEE Japan, pp.807 83 (200) 8 Y. Nagatsuka, S. Noguchi, Y. Kaneko, S. Abe, T. Yasuda, K. Ida, A. Suzuki, and R. Yamanouchi: Contactless Power Transfer System for Electric Vehicle Battery Charger, Proc. of 25 th World Battery, Hybrid and Fuel Cell Electric Vehicle Symposium and Exhibition (EVS-25), shenzhen China (200) 9 M. Budhia, G.A. Covic, and J.T. Boys: A New Magnetic Coupler for Inductive Power Transfer Electric Vehicle Charging Systems, IEEE IECON 200, pp.248 2486 (200) 0 G.A. Covic, J.T. Boys, M. Budhia, and C.-Y. Huang: Electric Vehicles- Personal transportation for the future, Proc. of 25 th World Battery, Hybrid and Fuel Cell Electric Vehicle Symposium and Exhibition (EVS-25), shenzhen China (200) T. Fujita, Y. Kaneko, and S. Abe: Contactless Power Transfer Systems using Series and Parallel Resonant Capacitors, IEEJ Trans. IA, Vol.27, No.2, pp.74 80 (2007-2) (in Japanese), D, Vol.27, No.2, pp.74 80 (2007-2) 2 Y. Kaneko, S. Matsushita, Y. Oikawa, and S. Abe: Moving Pick-up Type Contactless Power Transfer Systems and their Efficiency using Series and Parallel Resonant Capacitors, IEEJ Trans. IA, Vol.28, No.7, pp.99 925 (2008-7) (in Japanese), D, Vol.28, No.7, pp.99 925 (2008-7) 3 Y. Kaneko and S. Abe: Contactless Power Transfer Systems, IEEJ Journal, Vol.28, No.2, pp.796 799 (2008) (in Japanese),, Vol.28, No.2, pp.796 799 (2008) 987 0 5 200 3 4 5 IEEJ Trans. IA, Vol.32, No., 202

EV 987 9 2009 3 20 3 952 2 974 3 ITS 999 2007 2009 965 6 22 987 3 989 3 990 4 995 2 2000 4 2008 4 958 7 3 98 3 949 3 29 97 6 976 997 200 2004 4 985 IEEE 6 IEEJ Trans. IA, Vol.32, No., 202

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