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Chinese Journal of Electrical Engineering, Vol.4, No.

4, December 2018

Battery Charging Method for Electric Vehicles:


From Wired to On-Road Wireless Charging
Kishore Naik Mude*
(Solace Power Inc., 1118 Topsail road Mount Pearl, Newfoundland and Labrador, A1N5E7, Canada)
Abstract: Recent fossil fuel shortages and global warming related problems have caused a
substantial shift from internal combustion engine vehicles towards EVs. This paper explores the
thorough review of battery charging infrastructure from wired connection to on-road wireless charging
for an EV. The initial part of the paper deals with the wired charging and its power electronics
infrastructure. The later portion deals with the wireless charging where both static and On-Road types
are discussed. Furthermore, various aspects of wireless power transfer are also discussed. The Market
scenario and future growth prospects are reviewed and presented in last section of the paper.
Keywords: Wired charging, static WPT, on-road WPT.

1 Introduction Wireless charging has been attracting more attention


because of their advantages compared to the wired
The increase in price of oil and environmental counterpart such as no exposed wires, ease of charging,
issues has resulted in growing interest in clean vehicle and fearless transmission of power in adverse
technologies such as EV and Fuel cell EV[1]. As a result, environmental conditions[6].
electric vehicles(EV) are becoming a more attractive Depending on the charging time and power level of
solution than conventional vehicles(CV). EVs are the battery, EV charging is classified into four types
powered by electric batteries, which need to be namely mode1, mode 2, mode 3 and mode 4 charging[7-8].
recharged with electricity from the grid. It is clear that Mode 1 charging is considered as slow charging and
the EVs constitute a clear link between the electricity takes overnight. Mode 2 charging is typically described
and the transport sectors. Moreover, the EVs can provide as semi fast or nominal charging. Both mode1 and mode
a good solution to reduce the environmental impacts of 2 charging use single phase supply. Mode 1 charging is
transportation and energy dependency because they have generally installed at home, but mode 2 charging is
low energy consumption and zero emissions[2]. installed mostly at public places and shopping malls.
Generally, two types of battery chargers are used: Mode 3 and mode 4 are considered as fast charging
off-board and on-board battery chargers with uni- which typically use the three-phase supply and can
directional and bi-directional power flow. Most of the charge the battery in less than thirty minutes[9] .
battery chargers take a power from the utility grid, for Depending on various connections and plug type, they
this reason they often termed as unidirectional battery are classified as Case A, B, C and Type 1,2,3
chargers(UBCs)[3] . Unidirectional charging reduces respectively.
the interconnection issues and battery degradation. On Now a days, the concept of vehicle-to-grid(V2G)
the other hand, some battery chargers work in both has gained interest due to its ability of to supply stored
directions and these are called bidirectional battery energy to the grid[10]. It absorbs energy from the grid to
chargers(BBCs)[4]. These chargers support stabilization charge the battery during peak electricity production and
of power with proper power conversion. On-board delivers to grid when there is a peak electrical demand.
chargers can be used to charge from the utility outlet at EVs with BBCs are able to implement V2G concept as
the workplace or household plug or shopping malls bidirectional power flow capabilities of their battery
during the day time. Off-board charging is like a gas chargers. So, BBCs can work in two operating modes,
station used for conventional vehicles and thus its namely “recharge” mode when they absorb energy and
purpose is to charge fast. Compared to off-board “generation” mode when they deliver energy to grid.
charging, equipment is less for on-board charging. In recent years, interest in wireless charging
Charging of an electric vehicle can be performed by technology is growing for EV charging applications[11].
either wired(conductive) charging or wireless(inductive) It consists of two main stages, namely the transmitter
charging[5]. Wired charging uses metal contact between and the receiver, each of them having a coil coupled
electric vehicle supply equipment(EVSE) and the to the other one with an air gap between them. By
charging inlet of the vehicle. Even though wired Faraday’s law of magnetic induction energy will transfer
charging is popular, problems with messy wires and from the transmitter to receiver. Misalignment of coils,
safety concerns in wet environment are major drawbacks long charging times and degradation of the battery are
of this system. These problems can be overcome by major issues. The difficulties in static wireless charging
charging the battery of the vehicle without wires and this can be overcome by on-road charging and charge the
technology is termed as wireless power transfer(WPT). battery while in vehicle is moving which saves the
charging time and degradation problems[12].
*Corresponding Author, Email:kishore.308@gmail.com. On-road EV charging is an emerging technology
2 Chinese Journal of Electrical Engineering, Vol.4, No.4, December 2018

where one can charge their EV batteries while vehicle 2.2 Charging infrastructure-modes, cases and types
is on move[13-14]. Apart from their advantages such as
less battery requirements, they suffer a problem of The success of EVs will be highly dependent on
misalignment and further leads to synchronization whether charging stations can be built for easy access.
failures[15]. Various loading conditions, frequency mismatch, This is also critical for the potential grid supports that
misalignment and component tolerance are the main EVs can provide. The first place considered for charging
causes for the synchronization failure. stations should be homes and workplaces. Other
This paper is organized as follows: Section 2 potential locations with high populations include gas
considers the EV charging infrastructure and section 3 stations, shopping centers, restaurants, entertaining places,
Power supply infrastructures. Section 4 considers and highway rest areas, municipal facilities, and schools.
discusses wireless charging of EVs in static position and There have been various standards regarding the energy
section 5 refers to On-Road wireless charging of and transfer, connection interface and communication for EV
EVs. Section 6 discusses evaluation and the future scope charging.
and market scenario of battery chargers and section 7 Mode 1 charging is the use of a standard AC 110
concludes the paper. Volt (for US), 230V (for Europe and most of the world)
and not exceeding 16A household outlet. Electric
2 EV charging infrastructures vehicles come with on-board charging electronics, as
well as cords and equipment that allow the vehicle user
2.1 Types of battery charger to plug their car into an outlet in their garage. This is the
cheapest and most convenient home-based charging
Depending on the charging time available, chargers method, but it is also the slowest. Charging times vary
can be installed in houses, offices, shopping malls and greatly from vehicle to vehicle, but generally take
public places to enable EV owners to charge their EV. around 7~15 hours for a fully depleted battery to be at
Wired type EV battery chargers have direct connection full capacity. For example, if the driver of a Nissan Leaf
to the supply using an extension power cord to plug – which has about a 100-mile range – drives 30 miles
from the wall outlet into the EV. It is popular, simple in daily, the battery will only be depleted 30% each day.
design and highly efficient. The wireless battery charger Since Mode 1 charging will recover about 4.5 miles of
uses coupling as the mode of energy transfer. Through range per hour, the Nissan Leaf will be back to full
inductive chargers, a charging station is used to transfer charge after 7 hours. It is generally installed in
high voltage and current directly from the grid into an household garage. So, it doesn’t require special socket
inductive paddle or pad with an electro-magnet that acts for the charging the battery in USA, this method of
as half a transformer. The other half is situated inside the charging is prohibited as it requires earth connection.
EV and once full contact is made between the two Mode 2 chargers use a 230V or 440V AC mains not
magnets, the current is allowed to flow across and into exceeding 32A. It can be charged through charging
the battery, charging at a higher rate due to the charging stations often located in public places, such as at the
stations direct power grid connection. The charging shopping malls, restaurants, city parks, or even workplaces.
structure for the both chargers shown in Fig.1(a) and 1(b). Mode 2 charging is generally referred to as “opportunity
charging” because vehicle user usually uses this type of
charging whenever they have the chance. Mode 2
charging takes around 3~8 hours for a full charge and
nominal cost of installation of around $1000 to $2000.
Mode 3 charging is the fastest and most powerful
type of charging available. It typically operates with
three phase 440V supply and require off-board charger,
as a result, it provides a vehicle with a full charge in
minutes instead of hours. These charging stations are
used for EVs as well as large vehicles like electric buses,
(a) Wired charging and are found in public and commercial areas, airports,
and transportation corridors.
The scenario for Mode 4 charging is a setup where
the AC mains power is converted in the charging station
into d.c. and the plug type ensures that only a matching
EV can be connected. Using DC fast charging allows for
considerable higher currents up to 400A. A Japanese
protocol CHAdeMO is a d.c. fast charging standard
designed for EVs that complies with Mode 4 charging. It
charges in less than 30 minutes and up to 50kW with
communication management protocol. Infrastructure
cost of $30000 to $160000 has been reported[9].
Now, only Teslas can use the Tesla Supercharger
(b) Wireless charging network. Superchargers are installed widely across the
Fig.1 Wired and wireless charging[12] US(and Europe) and can charge an electric car faster
K. N. Mude: Battery Charging Method for Electric Vehicles: From Wired to On-Road Wireless Charging 3

than any other chargers out there. Tesla is quickly of the continuity of the protective earth conductor;
growing the Supercharger network, and this creates ③ Energization and de-energization of the system.
one large competitive advantage for the popular EV There are optional functions also provided by EVSE
company. At the moment, Tesla Superchargers have a including selection of the charging rate, determination
max power output of 120kW. of ventilation requirements of the charging area, detection/
Depending on method of charging infrastructure adjustment of the real time available load current of the
and connection, cases are classified as three types supply equipment, retaining/releasing of the coupling
namely Case A, B and C. “Case A”: connection of an EV and control of bidirectional power flow to and from the
to the a.c. mains utilizing a cable and a plug permanently vehicle. EV charging. Fig.3 shows the control function
attached to the EV. It is typically used with Modes 1 and and how EVSE is operated at different conditions.
2 charging. “Case B”: connection of an EV to the AC
mains utilizing a detachable cable assembly with a 3 Power supply infrastructures
connector (to be inserted in the EV inlet) and a plug (to
be inserted in the supply outlet). Case B1 corresponds to In order to charge a vehicle battery while considering
the connection to a wall-mounted socket-outlet. Case B2 the battery-charging characteristic and power factor
corresponds to the connection to a charging station. Case from the grid is seen unity, there are two categories
B connection is typically used with Mode 3 charging. among many circuit topologies: unidirectional battery
On the other hand, “Case C”: connection of an EV to the chargers(UBC) and bidirectional battery chargers(BBC).
a.c. mains utilizing a cable terminated with a connector In the UBC, the set of converters arranged from grid to
(to be inserted in the EV inlet) permanently attached to a battery, all are not active/controlled converters(i.e. made
charging station or a specific supply equipment. Only of diode rectifier) and they are not able to support
Case C is allowed for Mode 4 charging. bidirectional power flow. Therefore, these kinds of
Type 1 connector introduced by Yazaki(SAE J1772) chargers are less complex and can only fulfill the purpose
for charging the PEV battery from a single-phase supply. of charging the battery. The other type is bidirectional
Type 2 connector introduced by Menneskes(IEC 62961) chargers which have ability to charge the battery as well
for charging the PEV battery from single-phase 230V as transfer battery power to the grid in certain situations.
and three-phase 400V supply with current up to 63A[9]. The BBCs have active converters with bidirectional
Type 3 connector introduced by EV Plug Alliance: power flow, so these are more complex but also have
Scame/Schneider(IEC 62196) for charging from single more flexibility of power flow. Both UBC and BBC
and three-phase supply equipment. It has a maximum have circuit arrangement with and without electric
current of 32A and a safety shutter. There are two isolation between load and supply side converters. The
versions: Types 3A and 3C. Type 3A is for charging a isolated battery chargers use a high frequency transformer
light PEV battery(f.i. motorcycle) from a single-phase that provide galvanic isolation as well voltage-matching
supply with 250V and 16A; Type 3C is for charging (step up/down) between input and output side. The high
all-PEV battery from single and three-phase supply with frequency transformer has many other advantages like
up to 500V and 63A, all of them with control pilot. low volume, lightweight, low cost, less noise and reduced
"Type 4" – connector for fast d.c. charge(IEC 61851). It core saturation over a line frequency transformer.
is termed CHAdeMO like Mode 4 charging.
An electric supply equipment(EVSE) consists of
conductors, including the ungrounded, grounded, and
equipment grounding conductors, the electric vehicle
connectors, attachment plugs, and all other fittings,
devices, power outlets, or apparatuses installed
specifically for the purpose of delivering energy from
the premises wiring to the electric vehicle.
The control pilot sits in the charging cable
assembly connecting the in-cable control box or the
fixed part of the charging facilities and the EV earth
through the control circuitry on the vehicle. Functions (a) Equivalent circuit of control pilot
that shall be provided by the EVSE or the EVSE and
vehicle system are. ① Verification that the vehicle is
properly connected or not; ② Continuous checking

(b) Timing sequence


Fig.2 Schematic of cable and wire types[16] Fig.3 Control function of EVSE at different conditions[16]
4 Chinese Journal of Electrical Engineering, Vol.4, No.4, December 2018

3.1 Unidirectional battery charger converters, then the complete charger arrangement
becomes bidirectional. In the first stage, instead of a
A typical battery charger performs rectifying and diode rectifier, a fully controlled rectifier is then used as
power-conditioning operations of the power extracted it can perform bidirectional flow as well as the function
from grid. The input power of the charger is passed of power factor correction. In the same way in the
through a set of power converters, which include AC secondary side of transformer if full controlled converter
to DC(rectifier), DC to AC(inverter), or DC-to-DC is utilized instead of the diode bridge, the dc chopper
converters (chopper) according to the requirement. can be eliminated as shown in Fig.5.
Based on conversion stages, the chargers are again The first bridge converter in the supply side has full
classified in single stage, two stage and so on. Since flexibility to control DC bus voltage and power factor
battery chargers for vehicle application work with high with desired direction of power flow. Other two bridge
power and they have to follow fast charging strategy and converters connected with a high frequency transformer
grid power factor constraints as well, therefore not all performs the main function of this type of chargers. Both
this is possible in single stage. The multiple stages of a of these converters work with square wave pattern of
charger consist of rectification of ac power, power factor voltage and frequency in kHz. There is an inductor L
correction(PFC), DC to AC (high frequency) conversion, that works as temporary energy storage and it support
galvanic isolation, rectification and then DC-DC both converter to operate with soft switching. A good
conversion to meet charging strategy. A typical schematic design of converters and their components can ensure
of this process is shown in Fig.4. much less switching losses and in this way, good
The diode rectifier takes AC current from the utility efficiency is achieved. Because there are two controlled
and provides DC current to the next stage. There is a converters or active bridge across the HF transformer,
capacitor before the second stage of power conversion; this topology is called dual active bridge(DAB) battery
this keeps voltage of dc bus constant. Due to the charger.
constant dc bus voltage, the input ac current of the The DAB technology was initially proposed in
rectifier is not completely sinusoidal. The distortion in early 90’s when semiconductor devices were not well
input ac current leads to poor power factor at utility. In developed. Again, this is more popular today for
order to improve PF at input side, a power factor on-board battery chargers for EVs but there are still
correction(PFC) circuitry is introduced between dc bus some issues that are seeking more research interest.
and diode rectifier. The PFC is a dc-to-dc converter, One of the problems with DAB is circulating current in
which provides varying voltage conversion ratio to the transformer. When the voltage amplitudes of primary
maintain the shape of input current sinusoidal. and secondary do not match according to turn’s ratio,
High power chargers for EV batteries need isolation very small circulating current is flown, and this leads to
for safety reasons. The isolation is provided by a HF more losses and heat in the transformer and converters.
transformer, which works with some kHz frequency. This problem can be fixed using an appropriate phase
As shown in Fig., the inverter converts DC bus voltage shift scheme in primary side or secondary side or both
to high frequency ac supply to feed transformer input. sides of the converters. Some examples of phase shift
Another main function of the transformer is to step-down are single phase shift(SPS) where a certain phase shift is
voltage level, which is suitable for battery; this is not given between primary and secondary voltage, then
done by chopper, as it is less efficient. The secondary ac extended phase shift(EPS) where one additional internal
voltage of the transformer is rectified again with diode phase shift is given between 2 legs of one converter, one
rectifier. In the next and final stage, the rectified dc is dual phase shift(DPS) where an equal internal phase
voltage is fed to the battery and this is done by a DC shift is given in both converters. There is a unified
chopper. At the beginning of the charge, the chopper scheme of phase shift that is called triple phase
operates in current control mode; when the battery shift(TPS) where both primary and secondary voltages
voltage approaches its nominal value, the chopper enters have a phase shift with both converters have unequal
into voltage control mode and completes the charging internal phase shift.
process. Another big problem is range of soft switching of
3.2 Bidirectional battery charger both converters with varying load condition. Actually,
DAB has good efficiency at full load with a wide
The charger as discussed above and shown in Fig.4 voltage conversion ratio, but the soft switching range
cannot allow power flow in reverse direction, because of decreases as load current decreases. Therefore, under
uncontrolled diode rectifiers. If converters in all stages light load condition, various resonant techniques are
are kept bidirectional converters i.e. full controlled used as a solution to improve the range of soft switching.
The DAB combination is designed using some additional

Fig.4 Schematic of a full functioned unidirectional


battery charger [12] Fig.5 Schematic of a bidirectional battery charger[12]
K. N. Mude: Battery Charging Method for Electric Vehicles: From Wired to On-Road Wireless Charging 5

passive components (inductor, capacitor) such that it has though far field transfers large distances, they suffer
simple construction, lightweight, smooth, easy and from tradeoff between frequency and efficiency.
robust control, wide soft switching range and less Inductive technology, adopted in the so-called inductive
sensitivity with parameter variation. or resonant coupling WPTSs, is most convenient for
medium- and high-power equipment because it transfers
3.3 Integrated chargers a much higher energy per unit of volume than the
As charging and traction are not simultaneous in electric-field technology, and does it with much higher
EVs, except during the regenerative braking, the efficiency than the electromagnetic-field technology.
so-called integrated chargers are also applicable. They Simplified WPTS represents magnetic WPTS consist of
use the electric drive system components also during inductive WPTS and resonant WPTS.
charging. This leads to a significant reduction in volume, 4.2 Aspects of WPT
weight, and cost. This integration also allows galvanic
isolation, but both the power electronics and the control Present day WPT system for an EV, mainly focus
circuit of the integrated charger have to take care of the on the following aspects; ① Physics of WPT system;
reconfiguration of the electric drive systems. The aspects ② Efficiency maximization techniques; ③ Coil coupling;
that need further research are charger isolation, charging ④ Power supply requirement; ⑤ Safety and shielding
voltage control, unwanted magneto motive force
issues; ⑥ Communication requirements. Therefore, this
developed in the motor during charging, power factor
paper proceeds further with detailed explanation of each
operation, and harmonic content in the current from the
of the aspects. The detailed analysis is described as
grid, efficiency, and hardware/software complexity.
follows
4 Static wireless power transfer 4.2.1 Physics of WPT system
4.1 WPT: definition, structure and principle of Critical issues of the WPT system lie in understanding
operation of the physics, as it gives an overview of coupling
Wireless power transfer systems(WPTSs) are system design which plays a crucial role in development
systems able to supply a load with the electric energy of WPT system Different/various parameters.
absorbed from the grid without requiring any wired (1) Inductive parameters.
connection between load and grid. Due to enormous One of the key factors that define the performance
advantages compared to the wired charging, they are of WPTS is the coupling coefficient of the coils. It
particularly attractive for EV applications depends on the size and the shape of the coils and on the
The arrangement of a WPTS is sketched in Fig.6. distance between them. The magnetic flux density is
Transmitter coil is buried in the road and the receiver calculated between the two coils with a distance z
coil is located on-board the EV. When the vehicle is 0 2R 2
properly parked over the transmitter coil, the two coils B nI 
(1)
4
are coupled and energy can be transferred from the grid R  2
z2 2
to the battery, which acts as the load of the system.
By the Faradays law of magnetism, the emf will induce Where R is the radius of the coil and A is its cross-
in the secondary coil, which further charges battery section. The last expression of B in (1) holds when the
through power conditioning system. The elements in distance from the coil is much longer than the coil radius.
WPT system includes ① Utility grid with power If the magnetic induction magnitude is assumed constant
conversion system; ② Magnetic coupling system in across the coil cross-section, the self-inductance of the
transmitter and receiver; ③ Power conditioning system coil is
to charge the battery[17]. 0
L  n2 R (2)
The technologies encompassed with the WPTS are 2
electric[18], magnetic[19] and electromagnetic fields[20]. where n is no. of turns. The mutual inductance between
These technologies broadly classified based on two equal coils set coaxially at a distance d, much longer
underlying mechanism, transmission range and power than R, is
rating. Based on power transfer distance these are
classified into near field and far field. Laser, Microwave  R 4
M  kL  n 2 0 3 (3)
and RF are considered as far-field methods. Inductive, 2 d
capacitive technologies consider as a near field. Even Figure of merit (FOM) is another important aspect in
the wireless power transfer and [67] give the power loss
in the WPT

2
(kQ) 2

1  1  (kQ) 2  (3a)

The graphical figure for the Eq.(3a) shown in


Fig.7(b) which shows it is only dependent on the two
Fig.6 Schematic of WPT system[17] basic parameters of the WPT: The coupling factor k,
6 Chinese Journal of Electrical Engineering, Vol.4, No.4, December 2018

In the case of using magnetically coupled system


for powering EVs, a large air gap is required to allow for
inconsistency in the road surface and better clearance
between the road and vehicle. Because of this large air
gap, the leakage flux is very high, and the coefficient of
coupling is from 1% to 3% only. Such applications are
classified under loosely coupled systems and poor
coupling in loosely coupled systems leads to poor
transfer of power. To improve coupling and compensate
leakage inductance, capacitive compensation in primary
and secondary windings is required.
If the conductor is composed of one or more
concentric circular elements, then the center portion of
the conductor will be enveloped by a greater magnetic
flux than those on the outside. Consequently, the
self-induced back EMF will be greater towards the
center of the conductor, thus causing the current density
to be less at the center than at the conductor surface.
This extra concentration at the surface is known as skin
effect, and results in an increase in the effective
resistance of the conductor. The skin depth, δ, is defined
as the depth at which the current density falls to 1/e,
(about 0.37), of the current density at the surface. This is
given by

2
 (4)

(c) Frequency vs Q where ρ is the resistivity of the material and is related to
Fig.7 The relationship between parameters of the WPT [67] the conductivity as 1/σ, μ is the permeability of the
material and ω is angular frequency of the electrical
between the receiver and transmitter coil and the system solicitation.
quality factor Q. Moreover, from the equation, it can say
that the general FOM is product of k and Q. 4.2.2 Efficiency maximization techniques
(2) Near field and far field. It can be observed that quality factor and coupling
Near fields[21-22] can be seen as the reactive field coefficient plays a major role in determine the efficiency
surrounding any electrically charged object. In the static of WPT system that maximizing efficiency techniques
case, these fields are simply the electro-static fields, such as. ① Use of ferrite disks[25]; ② Compensation
while in the non-static case they form time varying techniques by placing a capacitor[26-27]; ③ Power
electric and magnetic fields, which are out of phase electronics control[28]. The detailed realization of above
close to the object (closer than λ) and can be used to methods is explaining in following sections.
induce current in near-by objects. In contrast to the In an inductive WPT, without secondary resonant
far-field waves, near-fields represent zero energy flow capacitors, the Power transfer to the load cannot be
according to the Pointing vector due to the 90-degree sufficient unless the input voltage is large. The reason is
phase difference between the electric and magnetic that the impedance of the receiver coil is quite large and
fields[23]. This gives nearfields an advantage in efficiency, therefore is responsible for a significant current drop in
as they do not radiate energy away from the source the load resistance. The best way is to increase the input
(3) Loosely coupled and tightly coupled. voltage so that the power transferred to the load is
If all the flux links the secondary, then k is 1 and if sufficient, but this solution is not optimal because it
none of the flux links the secondary k is 0 i.e. 0≤k≤1. requires higher current amplitudes in the primary coil,
Based on the values of k the magnetically coupled which in turn generates greater Joule losses. This may
system can be classified into two categories, namely lead to dramatic results in terms of efficiency and Joule
tightly coupled systems and loosely coupled systems. losses. Compensation topologies can be classified
In tightly coupled systems, such as transformer and depending on reactive structures into single-resonant
induction motor, the primary is placed in proximity of (SRT) and multi-resonant types(MRTs). The single-
secondary and flux is shaped by placing windings on the resonant structures shown in Fig.8(a) associate a
core of high magnetic permeability. Therefore, they have capacitor to each coil whereas multi-resonant Fig.8(b),
mutual inductance greater than the leakage inductance. Fig.8(c) topologies employ multiple reactive components
Because of tight coupling, k usually lies between 95% to in the transmitter and/or the receiver side. The two
98% for the transformer and approximately 92% for the compensation capacitances CT and CR for the main
induction motor[24]. topologies give two degrees of freedom in the system. In
K. N. Mude: Battery Charging Method for Electric Vehicles: From Wired to On-Road Wireless Charging 7

addition to their simplicity, there exists a wider study on (2) Coil impact parameters.
the single-resonant structures so that some design Coil parameters such as geometry that includes
guidelines have already been identified in [29]. diameter, no. of turns and coil material are important
Among the three categories, TWERT is a promising evaluating parameters of the design process. Coil
topology because with SRT required reactive power geometry of WPT influenced by coil material and
compensation and complex methodologies with THERT. optimizing coil material can improve the system
The efficiency is well explained in the Table 1, and the performance. Copper Litz wire is commonly used in
comparison of various parameters for the TERT is most of the systems and multi-layer, multi-turn tubular
tabulated in Table 2. coils have been adopted for improving the transmission
4.2.3 Coil-coupling efficiency, with a study of the skin effect.
The method of approach for coil design must
(1) Sizing issues. constrained to following points:
Coil coupling is heart of the WPT system design. ● The inductance and power capability must meet the

Prior to design of the coupling system, one must have category requirements, including the working frequency
clear idea of the behavior of coil impact parameters such and transferring power.
as coil design, core design, and coil alignment. The ● The mechanical dimension must fit to the target

impact parameters are influenced by such as coil application, including the coil area and thickness.
material, dimensions of the coil, core, and misalignment. ● The coil must provide the electromagnetic shielding

Careful study of these parameters are useful for the best for the associated electronic device, such as the
coupling system design. mobile phone.
● Durable construction.

There is generally a trade-off between coil size,


performance, and cost. Coil size and cost are inversely
related smaller coils give a better performance, but at a
higher cost. Coil structures can also influence the
performance of the system. Spiral coil, flat coil, square
(a) Single element resonant topology(SERT) coil, circular and DD coils have different performances
according to the studies in [30].
As an example, for the mentioned dimensions of 15
turns and with round wire cross section, inductive
parameters of different shaped coils are built as shown
in Fig.9. The turn distance in all the coils is kept 7mm
(b) Two element resonant topology(TERT) (center to center). The values of inductive parameters
simulated by COMSOL are mentioned in Table 3 for
these spiral coils.
(3) Cored coupling.
To enable higher coupling coefficient and to direct
the magnetic flux lines in proper direction, ferrite cores
are used. Ferrite cores are utilized because of their
(c) Three element resonant topology(THERT)
properties of high magnetic permeability, useful in
Fig.8 Example of different types of directing the flux, and low electrical conductivity that
resonant compensation topologies
mitigates the magnetic losses under high-frequency flux
Table 1 Efficiencies of different topologies[29]
cycles. Different ferrite core structures are illustrated in
literature, for example, in [30], cores having the I, C and
Topology Efficiency (%)
E sections shown in Fig.9, have been examined.
Series-series 94.6
Series-parallel 94.6 Table 3 Inductive parameters of different types of coils
Parallel-series 87.5
Shapes
Parallel-parallel 82 Paramters
LCC-series 94.2 Square Hexagonal Circular D-D shape
LCC-parallel 94.3 Self-inductance L/µH 86.0290 58.8241 73.672 53.449
LCC-LLC 93.5 Mutual inductance M/µH 17.1589 8.8950 12.199 9.5461
Coupling coefficient k 0.1995 0.1512 0.1656 0.1786
Table 2 Comparison of topologies[26]
Characteristics SS SP PS PP
Efficiency High High Low Low
Power supply sizing factor High Low Low Low
Receiving coil sizing factor Low High High Low
Per unit load current High Low Low High
Load dependency No Yes Yes Yes
Circuit impedance Min. Min. Max. Max.
Fig.9 Core structures(I, C and E) [30]
8 Chinese Journal of Electrical Engineering, Vol.4, No.4, December 2018

The difference between the coupling coefficient for Fig.11 shows the behavior of coupling coefficient
coreless and cored coupling for the varying the no. of vs coupling coefficient. Which shows the coupling
turns is examined. For the fixed distance of 0.15m, the coefficient decreases with increase in misalignment
coupling coefficient of cored coupling is 75% more than scenario handled by the various researchers mainly by
the coreless case[31]. power electronics control circuitry and with compensation
(4) Coil misalignment. topologies Compensation circuits are placed in the
Clearly, coil orientation (alignment) is one of the primary and secondary side to improve power transfer,
major issues for EV charging application. Because of the efficiency, voltage regulation, controllability etc[33].
tolerance in the vehicle-parking maneuver, the receiver
coil may be not perfectly aligned with the transmitter 4.2.4 Power supply requirements
coil during charging. This leads to a coupling coefficient (1) Frequency selection.
lower than the nominal one with a consequent decrease For effective wireless power transfer a high
of the efficiency in the power transfer. For EV charging frequency alternating current is necessary. This frequency
applications, as with the tolerance in the vehicle-parking is in the order of 10kHz to 100kHz, which is much
maneuver, the receiver coil may be not perfectly aligned higher than the 50Hz of the electrical grid. The desired
with the transmitter coil during charging. This leads to a frequency is achieved by combining a rectifier with an
coupling coefficient lower than the nominal one with a inverter. In order to keep losses at a minimum soft
consequent decrease of the efficiency in the power switching was preferred (today WBG devices), where
transfer the transistors of the inverter only switches on or off
Fig.10(a), (b) and (c). Shows the coupling coefficient when the current is zero. The specification on the
behavior of the 4-coil systems for coil distance, lateral operating frequency follows from the recent resolution
misalignment and angular misalignment conditions. of the SAE International J2954 Task Force for WPT that
fixed at 85kHz the nominal frequency of operation of
the WPT systems for light-duty plug-in vehicles[34].
(2) Power converter.
At first on the primary side, Power Electronic
System (PES) converters having utility frequency i.e. 50
or 60Hz which is converted to high frequency AC
(greater than 20kHz). Either a single stage or two stage
can do this. In single stage, power conversion is done
directly from low frequency AC to high frequency AC
using AC-AC cycloconverters while, two stage can be
done by initially converting AC to DC and then DC to
AC conversion performed by high frequency inverter.
(a) Distance The DC-AC converters are commonly used to
generate a high frequency current on the primary side of
a WPT system. Practically, there are two approaches to
achieve high frequency current generation: linear
amplifiers or switch mode power converters. In the
former case, the semiconductor devices are operated in a
linear region. Even though the development of different
classes of linear electronics amplifiers provides various
improvements, the nature of high power loss in linear
region limits a linear amplifier to low power
applications, where power efficient is not so important.
Comparing to linear amplifiers, switch mode power
converters can achieve high efficiency by fully on/off
(b) Lateral misalignment control. Therefore, switch mode power converters are
widely used to generate high frequency track currents
for medium or large WPT applications, where the power
efficiency is one of the major concerns.

(c) Angular misalignment for the 4-coil system[32]


Fig.10 Coupling coefficient for the Fig.11 Coupling coefficient vs misalignment [31]
K. N. Mude: Battery Charging Method for Electric Vehicles: From Wired to On-Road Wireless Charging 9

Numerous switch mode power converters are in the same leg. Primarily this ensures that the full
currently being deployed to generate high frequency bridge does not suffer from current shoot through, where
track currents for WPT systems. The input power source it otherwise would have issues at time periods where
for a switch mode high frequency power converter can both the upper and the lower transistor in the same leg
be either a DC or directly from AC mains. Thus, the are open, i.e. the supply is short circuited. The main
switch mode power converter for a WPT system can point about phase-shifted control in comparison with
be commonly classified further into two categories using conventional pulse width modulation(PWM)
according to the type of their input sources. They waveforms is the possibility to not only control the duty
are DC-AC inverters and direct AC-AC converters. cycle but also add some degree of control of the
Practically, because a direct DC source is not ubiquitous switching losses.
for accessing to generate high frequency currents, at (3) Losses in converter.
present most of the power converters used for WPT Loss analysis is very important for any power
systems are two stage AC-DC-AC converters. To obtain electronics system. Due to the increasing use of power
a constant DC power source, a front-end AC-DC electronics in a wide range of applications, power loss
rectifier is needed. In addition, energy storage elements measurement with high accuracy is of great importance
are necessary to link the rectification circuits and the in the design process to assess system performance and
DC-AC inverter to buffer the difference between the to optimize design characteristics. To measure the total
instantaneous input and output power within a two-stage loss of the system it is necessary to have the idea of
converter. In order to meet the requirements of losses of individual devices of the system.
international standards and improve efficiency, many Losses in the converter have two types, namely the
methods are applied to the AC-DC conversion stage, conduction losses and switching losses. When switching
such as synchronous rectifiers, filters, power factor the inverter at the resonance frequency, resonant
correction circuits, etc. Once a stable DC power is switching takes place i.e., ZCS and ZVS can be
obtained, a second stage DC-AC inverter is required for accomplished thereby reducing the switching losses
the high frequency track current generation. during the switching on and/or switching off. This also
A PWM hard switching technology is commonly makes it possible to operate the converter at high
used in the design of power converters. Using such a switching frequencies when compared to hard switching
switching technique, the on and off transients of the PWM converters.
switches may take place at non-zero voltage or current The other losses associated with the converter are
instants leading to a hard switching operation. In the conduction losses that are dependent on the type of
addition, during the on and off switching transients, the switches used. In case of SiC MOSFETs, the conduction
semiconductors have to withstand high voltage and losses are dependent on the current flowing through the
current simultaneously resulting in high switching losses switch and the on state drain to source resistance.
and stress. Passive inductive or capacitive components Researchers have approached the system analysis aspect
can be used as snubbers of semiconductor switches to of WPT[35], studied the effect of multiple receivers on
reduce the switching dv/dt and di/dt. Any variation of the transmitter and how the system can be better tuned
the dead time caused by the switching control. by optimizing the load variations.
The inverter is a full bridge inverter shown in (4) Control techniques of converter.
Fig.12, based on an existing Phase shift full bridge There are various techniques used to control the
inverter, where the phase shift is driven to be as close to output power and frequency of the system which
100% as possible. This inverter is designed for a higher includes fixed frequency and variable frequency.
voltage and power level but approximately the same Different control methodologies such as voltage control,
load current. duty cycle control, frequency control and phase shift
The term phase shifted full bridge relates to a control. The advantages and disadvantages of different
control scheme where both legs are separately driven to techniques are tabled in Table 4.
a duty ratio very close to 50% and then phase shifted The main issues regarding type of converters are
against each other than the 180 degrees shift between the how they affect the various performance parameters.
two legs’ waveforms there is also a delay between the Various literature[36-37] deals with uncontrolled rectifier
turn off of one transistor and the turn on of the other one with power factor correction circuits[38-39] and the other
Table 4 Comparison of different control schemes
Control Scheme Advantages Disadvantages
Simple, good current Poor efficiency due to two
Voltage control waveform on complex conversion stages, more
current distribution components
Duty cycle Simple to design without Serious current harmonics
control front end power converter and floating
Non-linearity, not able to
Frequency Applicable to high power,
maintain operating frequency
control simple to design
under resonant condition
Relatively complex but
No front end converter,
Phase shift manageable control scheme.
so high efficiency and
control Can only applicable to full
low EMI
Fig.12 Full bridge inverter bridge inverter
10 Chinese Journal of Electrical Engineering, Vol.4, No.4, December 2018

hand uses the controlled rectifier. The previous one field, and so the net magnetic field in the vicinity of the
mostly used topology for its simplicity with less control loop is reduced. Fig.13 shows the behavior of magnetic
mechanism rather than latter ones requiring the complex flux density for three cases i.e. without shield, with
control mechanism[40-42]. ferrite shield and with both ferrite and aluminum
In the receiver side, the transmitted power is shielding.
converted to DC by using the AC-DC converter, which
may be controlled, or uncontrolled[43]. DC-DC chopper 4.2.6 Communication and standards
can do the regulation of power level according to battery In terms of communications and standards for
specification and the ripple content can be decreased by wireless power transfer, relev ant work in development
inserting a capacitor across the load[44-47]. includes IEC 61980-2 SAE[57] between Plug-in Electric
The control mechanism and regulation of converters Vehicles and the Utility Grid. Communications for
are important aspects in WIPTS. The control method of wireless charging will use DSRC(Dedicated Short
a wireless charging system is an important topic closely Range Communications). This is a coordinated effort
related to power electronics converters[48-49]. Many between US DOT, SAE DSRC Committee as well as the
control methods have been developed in stationary SAE Communications Committee, and will open up
charging systems as well as dynamic charging systems. numerous opportunities for electric vehicles. The firms
In the stationary charging applications[50-51], the control working in different part of world and their technological
methods are designed to achieve high system efficiency, relevance is summarized in Table 6.
desired outputs, and bidirectional power transfer between
grid and battery packs[52-53]. On the other hand, for 5 On-road WPT (ORWPT)
dynamic WIPTS applications, control and regulation
have been developed to solve the synchronization and From the vehicle viewpoint, ORWPT enables
misalignment problems[54-55]. infrastructure where EVs can be charged continuously
while in motion, However, employment of such system
4.2.5 Safety and shielding issues is reliant on the infrastructure development, which in
The design of the magnetic field distribution is also turn is limited by its cost. The schematic diagram of
a significant factor in a WPT system, particularly in a ORWPT is shown in Fig.14. In addition, the amount of
high-power transfer system. As a magnetic flux of more
than thousands of mill tesla from the current of
thousands of amperes is generated between the transmitter
and receiver coils, even 0.1% of leakage from the main
flux can be hundreds of milli tesla, which is several
times larger than the magnetic flux regulation suggested
by the International Commission on Non-Ionizing
Radiation Protection [55]. Therefore, it is essential to
control the leakage magnetic flux for WPT applications
the shielding will be mainly added under transmitter and
above the receiver is important for the safe operation of
WPT. Without shielding, following problems may occur:
① The magnetic field may interfere with the device or (a) Without shielding

other objects; ② May cause battery heating and ③ It


may circulate current in metallic parts.
There are two basic methods for shielding against
low to medium frequency magnetic sources, which
includes diversion of the magnetic flux with high-
permeability materials[56] and the generation of opposing
flux via Faraday’s law. Assuming the external medium
is free space with μ =μ0 and the shield is constructed of
a ferromagnetic material having μr >>1, the magnetic
field will tend to concentrate in the low-reluctance
(b) Shielding with Ferrite
ferromagnetic path, and as such will be diverted from
affecting the free space region. To achieve this effect,
the ferrite plate has to be thick enough; otherwise, the
leakage flux into free space is considerable. An
alternative to the mentioned above is the field
distribution when an aluminum sheet is attached to the
ferrite plate. According to Faraday’s law, a current
circulates in the aluminum sheet and associated
magnetic flux is generated.
The induced magnetic flux is of a polarity or (c) Shielding with ferrite and aluminum
direction as to counteract the original incident magnetic Fig.13 Magnetic field distribution
K. N. Mude: Battery Charging Method for Electric Vehicles: From Wired to On-Road Wireless Charging 11

It is necessary to track the receiver position and


switch the appropriate power source as the load moves
along the array. In addition, separation between
transmitter coils needs to be carefully optimized. When
coils are placed too apart, efficiency reduces steeply and
when the receiver moves away from the transmitter and
power transfer will not be continuous. However, coils
Fig.14 Schematic of IM-WPT system cannot be kept too close to each other due to two reasons.
Firstly, negative mutual inductance to all between
energy gained through WPT depends on the power level adjacent transmitter coils are significant generating
of the system[58-60], vehicle speed and duration that vehicle negative[62].
travel. In general, ORWPT track can be categorized into Apart from charging issues, the ORWPT requires
two types; elongated track and segmented track[61]. The controlling and design of driving cycles of the vehicle,
first type consists of a substantially long transmitter charging lane length and its performance over a range of
track connected to a power source. Segmented track has the driving cycles. In [63], researchers are considered
multiple coils connected to high frequency power three driving cycles (UDDS, HWFET and VAIL2NREL)
sources as shown in Fig.15. The single transmitter track and the three type of vehicles (compact car, large car and
SUV). Several power levels for the charging station
can be few meters to several tens of meters long.
were tested (up to 60 kWh); the results are the optimal
However, this type of design suffers from several
length of the charging lanes, location in the drive cycle
drawbacks. Firstly, the electromagnetic field emitted
and battery size. It was concluded that when minimum
within the uncoupled region has to be suppressed to
track length is the only optimization criterion the track
eliminate harmful exposure. Secondly, the compensation
length becomes very short. Therefore, it is beneficial
capacitor has to be distributed along the track to
to size the batteries to easily meet the peak power
compensate large inductance. This brings additional
requirements.
constraints in construction. Thirdly, coupling coefficient
Korea Advanced Institute of Science and Technology
is low because of the smaller transmitter region covered
(KAIST) proposed online electric vehicle(OLEV) which
by the receiver resulting lower efficiency. On the other
passed through many generations and they used various
hand, segmented track eliminates issues raised by single
types of ferrite cores like U-type, E-type and I-type and
transmitter track such as field exposure and requirement
coreless. Present generation uses coreless for transmitter
for distributed compensation while lowering coupling
and receiver. Supply lines are twisted to each other and
issues. However, it introduces the design challenges creates alternating poles in the track. This phenomenon
such as synchronization between track and pickup. In reduces leakage inductance and unwanted EMF. In
addition, separation between transmitter coils needs to the pick side, there is a couple of coils which covers
be carefully optimized by placement of the segmented consecutive poles to make the magnetic path complete.
coils on track. However, coils cannot be kept too close The main point of this arrangement is narrow width
to each other due to two reasons. Firstly, negative transmitting track and wide pickup[64-65]. The transmitting
mutual inductance between adjacent transmitter coils is poles produce magnetic field which is spread in a wide
significant generating negative current stress. Secondly, area towards the pickup. The deployment is shown in the
design cost will be increased with many transmitters in a Table 5.
given length of the track. On the other hand, designing Another solution for OR WPT found in research is
the Power supply such as HFI for each segmented track based on field containment by source-receiver interaction.
is not a feasible solution. In addition, integrating the There are many coils are distributed along the road and
control of overall mechanism with synchronization supplied by a single inverter. These coils have high
poses major design challenges. self-inductance and the supply frequency is high, so only
a small amount of current flows in these coils in normal
conditions due to high uncompensated reactance.
Another situation when a pickup coil appears in vicinity
of a transmitting coil, the reactance of secondary coil is
reflected into primary side. This reflected reactance
can be adjusted by compensation of secondary circuit

Table 5 Various generations of OLEV[62]


Generation
Parameters
1G 2G 3G 4G 5G 6G(in progress)
Core type E U W I Ultra-slim-S coreless
Efficiency (%) 80 72 83 74 72 N/A
Distance/cm 1 17 20 20 20 10~ 20
Power/pickup/kW 3 6 15 27 22 3.3
(b) Segmented track
Fig.15 Elongated and Segmented track [65] EMF generated/mG 10 51 53 <10 <10 N/A
12 Chinese Journal of Electrical Engineering, Vol.4, No.4, December 2018

and this also can compensate primary side reactance. loose cords or potential for electrocution or tripping; no
When a pickup coil is coupled with a primary coil and adverse human safety or health impacts (as long as
compensates its reactance, current in the primary coil emissions of and exposures to magnetic and electric
increases. The increased current in coupled coils fields and radiation comply with applicable guidelines,
creates a strong magnetic field and power transfer standards and regulations).
happens. Fig.16 shows the Market scenario of the Wireless
Compensation using the reactance of other coil is Power Transfer industry. The graph reveals that, by end
an attractive solution to eliminate switching and sensing of 2020, the market will increase enormously and for
arrangement when vehicle passes through a particular the applications of the electric vehicle, the growing rate
part of the track. In other words, it doesn’t require is increasing about 6%~10% every year. In 2017,
receiver position tracking system. Moreover, since the Mercedes-Benz(Germany) is expected to launch the
magnetic field generated by a primary coil is much less luxurious hybrid-powered sedan car(probably from
when no pickup is coupled, unwanted EMF remains S-Class series) that is enabled with the wireless charging
inherently under control. The receiver coil circuit is technology. BMW AG(Germany) is also on the list of
designed such a way that transmitting coil reactance can future wireless charging car manufacturers. Toshiba
be compensated completely. The receiver is tuned based Corporation also had a trail run for 45-seaters electric
on the operating frequency of primary supply and it bus for wireless charging. The contactless charger based
reflects resistive and reactive impedances back to the on the magnetic resonance technology is designed in
primary. Only resistive component is reflected when its association with the Waseda University.
series compensation, and in parallel compensation case Europe, being one of the early adopters of this
the reflected impedance is technology, is expected to grow at a high rate. Europe is
the automotive hub, and the developments in the
Vr 0 M 2 European market, especially in electric vehicles and
Zr   (Q  j ) (4)
Is L2 wearable electronics, are expected to boost the growth of
the wireless power transmission market in this region.
Nevertheless, the reflected reactance results in The European Green Vehicles Initiative Association
higher power supply VA rating, and therefore, increased (EGVI), a Europe-based company, has undertaken
inverter current, without contributing the real power to
the load. This is considered as the disadvantage of the
parallel-compensated receiver. Therefore, some different
series-parallel combinations are preferred to achieve
more power transfer and better efficiency.

6 Evaluation, future prospective of wireless


charging
Recent reviews of WPT technologies and their
transportation applications are optimistic about their (a) Market scenario by application
prospects for deployment and growth. A promising
strategy for competing WPT technology providers is to
enter into partnerships with bus or LRV manufacturers
in order to demonstrate in service operations, their
commercial reliability, cost-effectiveness, and market
niche viability. From this WPT review of emerging and
existing transit applications in the U.S. and worldwide,
it is evident that there are multiple candidate WPT
technologies for transit applications in various stages of
technology maturity: from development to prototype
test/evaluation, to some in-service deployment.
Progress in WPT products standardization and the (b) Market scenario by the continent
harmonization of international WPT standards will
broaden market access to competing EVSE and on-board
products for electric light duty and heavy-duty vehicle
applications, including public bus and rail transit as a
market niche. WPT developers and technology providers
claim multiple core benefits for EV owners and electric
transit operators and users that are yet to be proven in an
operational environment, including convenient choice of
fast (On-Road) or slow (in station or depot), battery
recharging with one infrastructure system; automatic
trigger of charging high power transfer potentially in all (c) Cost returns of WPT (In-Motion)
weather, without corrosion or exposed terminals; no Fig.16 Market scenario of the WPT industry[66]
K. N. Mude: Battery Charging Method for Electric Vehicles: From Wired to On-Road Wireless Charging 13

Table 6 Various products and their relevance 2007.


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K. N. Mude: Battery Charging Method for Electric Vehicles: From Wired to On-Road Wireless Charging 15

fundamentals and technologies,” Dr. Eugen Coca (Ed.), In Tech, Kishore Naik Mude received his B.Tech.
DOI: 10.5772/64331. degree in Electrical Engineering from Sri
[63] Z. Pantic, K. Lee, and S. M. Lukic, "Receivers for multi Venkateshwara University, Tirupati, India,
frequency wireless power transfer: design for minimum in 2008, and his M.Tech. degree in Electrical
interference," IEEE Journal of Emerging and Selected Topics in Engineering from the Motilal Nehru National
Power Electronics, vol. 3, no. 1, pp. 234-241, 2015. Institute of Technology, Allahabad, India, in
[64] Z. Pantic, Sanzhong Bai, and S. M. Lukic, “Inductively coupled 2010. From 2010 to 2011, he was a Lecturer
power transfer for continuously powered electric vehicles,” at Amity University, Noida, India. He graduated
Proc. of IEEE Vehicle Power and Propulsion Conference his Ph.D degree in Electrical Engineering
(VPPC’09), pp 1271-1278, 2009. from University of Padova, Italy, in March
[65] P. Kumar, K. N. Srivastava, and A. Dhar, Role of Electric 2015. Presently he is working as senior electrical researcher with
Vehicles in Future Road Transpor. Sustainable Energy and solace power, Canada. Prior to this he was working with Systec
Transportation. Part of the Energy, Environment, and R&D, Porto, Portugal and he also served as an Asst. Professor in
Sustainability book series, Singapore: Springer, 2017. Amrita Vishwa Vidyapeetham University, Bengaluru campus,
[66] J. Meins, “German activities on contactless inductive power India. He received Prestigious European fellowship CARIPARO
transfer,” IEEE Energy Convers. Congr. Expo., 2013. sponsored by Italian Bank, for three years of his doctoral study. He
[67] https://www.navigantresearch.com/wpcontent/uploads/2012/07/ was invited for talk on Wireless Battery chargers in various
WPOW-12-Executive-Summary.pdf. Accessed online on 13/5/ organizations in India and abroad. His current area of research
2017. includes, Wireless Power Transfer, Battery chargers. He organized
[68] https://www.wirelesspowerconsortium.com/Accessed online on and chaired special sessions in the area of Wireless Power
25/05/2017. Transfer.

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