ORNL Developments in Stationary and Dynamic …...2014/03/19 · ORNL WPT Technology 22 In-motion...

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


Vehicle Implementations


Power Electronics for WPT


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)


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.


• 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


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


FOA #667 Phase I – Stationary WPT

Development


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


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 )


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


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)


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


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


Secondary P [W]125mm gap


Secondary P [W] 175mm gap


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



Bench Demo

• Test results @137mm airgap at 6.6kW

• Test results @160mm airgap at 6.6kW



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


LDRD WPT Program – In-motion WPT

Demonstration


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


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




• 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



• 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


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)


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



• Current ripple smoothing with Li-ion capacitors on the grid side unit and carbon electrochemical ultra-capacitors on the vehicle side.



• 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


ORNL WPT Development for the

Sustainable Campus Initiative



• 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



• HMI installation into a PRIUS PHEV demo vehicle

– Vehicle CAN accessed and battery status and related information provided to in-cabin display


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


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


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

mailto:[email protected]



ORNL Developments in Stationary and Dynamic …...2014/03/19 · ORNL WPT Technology 22 In-motion...

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