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 Modeling Wireless Power Transfer in ANSYS

1 © 2012 ANSYS, Inc. December 18, 2014

 Physical domains and systems

Electromagnetic domain

Thermal domain

Fluid Flow domain

Mechanical domain

2 © 2012 ANSYS, Inc. December 18, 2014

 Physical domains and systems

Receiver coil sub-system Transmitter coil sub-system

Load Circuit Circuit Power

supply

Control

3 © 2012 ANSYS, Inc. December 18, 2014

 Geometry

4 © 2012 ANSYS, Inc. December 18, 2014

 Wireless Power Transfer
Near-Field (Inductive coupling, resonant)
• Not based on propagating EM waves
• Operates at distances less than a wavelength of
transmission signal
• Resonance obtained by use of external circuit capacitor
• Typical challenges include: coil size, shape, number of
turns, saturation, self and mutual inductance, AC
resistance, frequency response, losses, efficiency

Far-Field (resonant)
• Microwave Type
• Operating range to ~10 meters
• Tradeoff between directionality and transmission
efficiency
• Self capacitance of coil turns is of importance

5 © 2012 ANSYS, Inc. December 18, 2014

 Method Map

Induction type (~15W) Induction type (~50kW)

100%
Efficiency

Resonance type
50%

Microwave type

0%
1mm 1cm 10cm 1m 10m 100m
Transfer Distance
Ref.：EE Times Japan 2009.10

6 © 2012 ANSYS, Inc. December 18, 2014

 ANSYS Solution for each WPT type

Induction type (~15W) Induction type (~50kW)

100%

Maxwell
Simplorer
Efficiency

Resonance type
50%

HFSS
Designer Microwave type

0%
1mm 1cm 10cm 1m 10m 100m
Transfer Distance
Ref.：EE Times Japan 2009.10

7 © 2012 ANSYS, Inc. December 18, 2014

 Large Gap Transformer Design Using
Computational Electromagnetics (CEM)

8 © 2011 ANSYS, Inc. December 18,

2014
 Transformer

• Low reluctance flux path is available

• Mutual Coupling between the coils can be
easily determined using Magnetic Circuit
approach
• Leakage flux can be considered to be
negligible
• Mutual inductance can be derived using
flux balance
• Analytical solution possible within
permissible level of accuracy

9 © 2011 ANSYS, Inc. December 18,

2014
 Large Gap Transformer

• No Specific path for the magnetic flux

• Leakage flux is significant enough and can
not be neglected
• Analytical methods are proposed for
calculation of Mutual inductance using
Maxwell’s formula for two coaxial circular
coils
𝟐𝟐𝝁𝝁𝟎𝟎 𝑹𝑹𝒑𝒑 𝑹𝑹𝒔𝒔 𝒌𝒌𝟐𝟐
𝑴𝑴 = 𝟏𝟏 − 𝑲𝑲 𝒌𝒌 − 𝑬𝑬 𝒌𝒌
𝒌𝒌 𝟐𝟐
𝑲𝑲 𝒌𝒌 , 𝑬𝑬 𝒌𝒌 are elliptical integrals of first and
second kind
Application of these formulas to real life cases is almost impossible

Computation Electromagnetics can help to reduce problem complexity

significantly - Maxwell
10 © 2011 ANSYS, Inc. December 18,
2014
 Maxwell

11 © 2011 ANSYS, Inc. December 18,

2014
 Graphical User Interface (GUI)
• Easy-to-use GUI
• Features entered through GUI
• Fast Learning Curve
• Integrated under ANSYS Workbench (WB)

12 © 2011 ANSYS, Inc. December 18,

2014
 Automatic Adaptive Meshing

Measured

13 © 2011 ANSYS, Inc. December 18,

2014
 Fields Calculator
• Allows any arbitrary mathematical manipulation of basic field quantities
• Allows to easily define any post-processing quantity

14 © 2011 ANSYS, Inc. December 18,

2014
 Post Processing

• Flexible and easy-to-use post-processing capabilities

• Field plots can be generated in volumes, on surfaces and on any defined planes. Mesh,
magnitude, vector and streamline plots of basic field quantities are readily available

15 © 2011 ANSYS, Inc. December 18,

2014
 Time domain analysis with motion
• Arbitrary time-dependent voltage and current excitations to drive the coils
• Measured waveform can be imported to be used as a coil excitation
• Maxwell is capable of modeling translational, rotational cylindrical and rotational non-cylindrical
(relay type) motion
• Equation of Motion can be considered

16 © 2011 ANSYS, Inc. December 18,

2014
 Inductive Type Coupling – Near Field

1) Electromagnetic analysis to determine R, L, M

C C

R R
Magnetic → R, L, M
L L
M

2) Resonant circuit realized by a lumped capacitance parameter in

the circuit simulator

17 © 2012 ANSYS, Inc. December 18, 2014

 Example

20kW @ 400V/20kHz

Core
Secondary Coil

Shield Plate Coil Primary Coil

18 © 2012 ANSYS, Inc. December 18, 2014
 Solution Flow Chart

Gap
Magnetostatic Sliding
Analysis
Core, Winding

Frequency domain
Analysis
Circuit Analysis
State-Space Model
AC / TR
Frequency domain
Analysis Circuit / Drive / Controller design
Waveform, Efficiency, Power
Field, Loss factor, Response
19 © 2012 ANSYS, Inc. December 18, 2014
 Magnetostatic Analysis using Maxwell

• A Static Magnetic analysis using

ANSYS Maxwell can calculate the
self as well as mutual inductances
of such a system
• Coils can be modelled as a lumped
objects to reduce the simulation
complexity

L1 M
M L2

20 © 2012 ANSYS, Inc. December 18, 2014

 Flux Density Distribution

21 © 2012 ANSYS, Inc. December 18, 2014

 Magnetostatic Analysis using Maxwell
Mutual Inductance L12 2D_Static_BH

Verification for core saturation

ANSOFT
1.00
Matrix1.L(C
[nH]

– Core’s BH curve, Mag_B field plot 3.4200e+004

2.8500e+004

– No magnetic saturation 0.10

Specification Area
2.2800e+004
1.7100e+004

Gap [meter]
1.1400e+004
0.60 5.7000e+003
0.0000e+000

0.50 0.01

0.40
B (tesla)

Nonlinear BH curve
0.30 0.00
0.00 20.00 40.00 60.00 80.00 100.00
Current [A]

0.20

0.10

0.00
0.00 100.00 200.00 300.00 400.00
H (A_per_meter)

As Maximum Flux Density is within linear region, cores can

be modelled as Linear magnetic material
22 © 2012 ANSYS, Inc. December 18, 2014
 Parametric Analysis
• In Example, we assumed that spacing between the coils is fixed and
axis of the sender and receiver is perfectly aligned
• In Practice,
– Distance between the coils can vary significantly
– Misalignments in coil axis can also be present

• Analysis needs to be performed to determine magnetic coupling

between two coils as function of the spatial location with respect to
each other

23 © 2011 ANSYS, Inc. December 18,

2014
 Parametric Analysis using Maxwell

24 © 2011 ANSYS, Inc. December 18,

2014
 Parametric Analysis using Maxwell

25 © 2011 ANSYS, Inc. December 18,

2014
 Parametric Analysis using Maxwell

Mutual Inductance Vs Gap

Vs Slide

Coupling Coefficient Vs
Gap Vs Slide

26 © 2011 ANSYS, Inc. December 18,

2014
 Eddy Current (Frequency domain)
• Impedance vs frequency
• State Space Model for Circuit Analysis
• Losses
• Eddy current shielding

Core(Power Ferrite)

Shield Plate (Aluminum)

27 © 2012 ANSYS, Inc. December 18, 2014

 Loss Calculation
Specifying Eddy Current Calculations in Shields

Define Electrical Conductivity for the

shields in Siemens/m
Shields are modelled as Aluminum in this
example and are specified with
Conductivity of Aluminum

Turn ON the eddy current calculation for

the shield objects

28 © 2011 ANSYS, Inc. December 18,

2014
 Loss Calculation
Specifying Core Loss Calculations in Core Plates

Input Core Loss vs Frequency data for the

range of frequencies that you wish to
operate on
Core Loss Coefficients are calculated
automatically

Turn ON Core Loss calculation for the cores

29 © 2011 ANSYS, Inc. December 18,

2014
 Loss Calculation
Core Losses in the Core Plates at 100 kHz

30 © 2011 ANSYS, Inc. December 18,

2014
 Frequency Sweep
• Once the Large Gap Transformer is analyzed in isolation, it
needs to be included in a system level simulation
• The model of the transformer represented on system level
should include the accurate representation as simulated using
CEM
• A state space representation can be extracted from CEM model
by defining a frequency sweep
• A frequency sweep will also help in analyzing system
performance to frequency deviations

31 © 2011 ANSYS, Inc. December 18,

2014
 Frequency Sweep

Core Loss Vs
Frequency

32 © 2011 ANSYS, Inc. December 18,

2014
 Large Gap Transformer Design Using
Computational Electromagnetics (CEM)

33 © 2011 ANSYS, Inc. December 18,

2014
 Coupling Simulation EM and Circuit
Model Generated by Field Simulator

＝
WM1 WM2
WM1 Cs WM2
+ + Cs R1
R1 R2
R2 + +
Current_1st_1:src
W W W W
Current_2nd_1:src
(1/87) ohm
1.87uF 1.93uF Current_1st_1:snk (1/348) ohm
(1/87-0.004) ohm (1/348-0.001) ohm
M1 Current_2nd_1:snk
E1 E1 L1Current_1st_2:src L2 Cp Cp Rload Rload
AMPL=200VAMPL=200V Current_2nd_2:src
FREQ=10kHzFREQ=10kHz 5.23uF 10ohm
0.19267mH
Current_1st_2:snk 0.048166mH 5.24uF 10ohm
0.5668
Current_2nd_2:snk

0 0
AC / Frequency
0
domain TR / Time domain 0

34 © 2012 ANSYS, Inc. December 18, 2014

 Circuit Design: Resonance Capacitor type

SS, SP, PS, PP type

Ref.: ANSYS Automotive Seminar, 30.Oct.2012, “Design of A Zero‐Voltage‐Switching Large‐Air‐Gap Wireless Charger for
35 © 2012 ANSYS, Inc. December 18, 2014 Plug‐in Hybrid Electric Vehicles”. Kevin (Hua) Bai, Department of Electrical and Computer Engineering, Kettering University
 System Simulation

THREE_PHASE1 IGBT1 D1 IGBT3 D3

D5 D7 D9
3PHAS WM1 WM2
A * sin (2 * pi * f * t + PHI + phi_u) + Cs R1 R2 +
Current_1:src D11 D13
PHI = 0°
W Current_2:src W
~ 1.72uF
7.2mOhm 3.6mOhm Rload

13ohm
Current_1:snk
PHI = -120° Current_2:snk
~ C1
Cp C2
4.96uF 1uF
1000uF
PHI = -240°
~ D6 D8 D10
IGBT2 D2 IGBT4 D4 D12 D14 - +
Battery

LBATT_A1

0 Wireless Power Transformer Battery 0

AC400V Rectify Inverter Curve Info rms

700.00 WM1.V
0 TR 281.0066

PWR_Probe1 WM2.V
321.9453
TRANS1 TR
TRANS2
STATE_11_1 STATE_11_2 PWR
Probe
FML_INIT1 200.00
ICA:

Y1 [V]
Modulation_Index:=0 PWR_Probe2
Carrier_Freq:=20k SET: TSV4:=1 SET: TSV4:=0
Frequency:=20k SET: TSV3:=0 SINE1.VAL < TRIANG1.VAL SET: TSV3:=0 DT1 PWR
SET: TSV2:=0 SET: TSV2:=0 Probe -300.00
Dead_Time:=2u SET: TSV1:=1 SET: TSV1:=0
DC_Source:=400 DEL: DT1##Dead_Time
SINE1
TRANS3

Controller
TRANS4
AMPL=Modulation_Index STATE_11_4 STATE_11_3
FREQ=Frequency -800.00
2.00 2.20 2.40 2.60 2.80 3.00
Time [ms]
TRIANG1
SET: TSV4:=0 SET: TSV4:=0
DT4 SINE1.VAL > TRIANG1.VAL
SET: TSV3:=0 SET: TSV3:=1
AMPL=1 SET: TSV2:=0 SET: TSV2:=1
FREQ=Carrier_Freq
SET: TSV1:=0 SET: TSV1:=0
DEL: DT4##Dead_Time 150.00 Curve Info rms
WM1.I
TR 41.6165

250.00 Curve Info Y Axis873.02

rms 100.00 WM2.I
TR 34.8648
WM1.I
TR Y1 38.9542

WM2.I
500.00 50.00
125.00 TR Y1 34.1140

WM1.V
Y1 [A]

TR Y2 276.0822
Y1 [A]

Y2 [V]

0.00 0.00
0.00 -0.0037 WM2.V
TR Y2 316.6292
-40.2840 -53.6971
-64.8250 -315.0105 -319.5653
-408.7847 -377.1247 -50.00
-125.00 -500.00

-100.00
-250.00 -1000.00
2.900 2.925 2.950 2.975 3.000
Time [ms]
-150.00
MX1: 2.9200 0.0610 2.00 2.20 2.40 2.60 2.80 3.00
MX2: 2.9811 Time [ms]

36 © 2012 ANSYS, Inc. December 18, 2014

 Efficiency Map

Output/Input Power
Tuned capacitance for each condition
Max.96%
P = VI cos θ
Pout 90%
η= ×100[%]
Pin Efficiency[%]
50%

Gap
20%
Sliding

Gap [mm] Sliding [mm]

37 © 2012 ANSYS, Inc. December 18, 2014

 Efficiency as a function of sliding direction and
distance
• Gap between coils kept constant

38 © 2011 ANSYS, Inc.

 Efficiency as a function of gap between coils

• Zero sliding
Gap

39 © 2011 ANSYS, Inc.

 Field solution using the currents from the
circuit simulation

Distance

Magnetic Field Intensity Magnetic Flux Density

XY Plot 1 2D_Eddy ANSOFT
10.00

Curve Info
Mag_B
1.00
Setup1 : LastAdaptive
Freq='20kHz' Phase='0deg'
Mag_B [mTesla]

0.10

0.01

0.00

Distance
0.00
0.00 0.20 0.40 0.60 0.80 1.00
Distance [meter]

40 © 2012 ANSYS, Inc. December 18, 2014

 Field solution using the currents from the
circuit simulation

Primary

Secondary

Core Losses Shield Losses

41 © 2012 ANSYS, Inc. December 18, 2014

 Summary
ANSYS offers a comprehensive modeling solution for Wireless Power Transfer
systems:
– Magnetostatic THREE_PHASE1 IGBT1 D1 IGBT3 D3

– Frequency domain
D5 D7 D9
3PHAS WM1 WM2
A * sin (2 * pi * f * t + PHI + phi_u) + Cs R1 R2 +
Current_1:src D11 D13
PHI = 0°
W Current_2:src W
~ 1.72uF
7.2mOhm 3.6mOhm Rload

13ohm
Current_1:snk
PHI = -120° Current_2:snk
~ C1
Cp C2

4.96uF 1uF
PHI = -240°
1000uF

– Circuit and system level

~ D6 D8 D10
IGBT2 D2 IGBT4 D4 D12 D14
- +
Battery

LBATT_A1

0 0

Curve Info rms

700.00 WM1.V
0 TR 281.0066

– Multiphysics
PWR_Probe1 WM2.V
321.9453
TRANS1 TR
TRANS2 PWR
STATE_11_1 STATE_11_2
Probe
FML_INIT1 200.00
ICA:

Y1 [V]
Modulation_Index:=0 PWR_Probe2
Carrier_Freq:=20k SET: TSV4:=1 SET: TSV4:=0
Frequency:=20k SET: TSV3:=0 SINE1.VAL < TRIANG1.VAL SET: TSV3:=0 DT1 PWR
Dead_Time:=2u SET: TSV2:=0 SET: TSV2:=0 Probe -300.00
SET: TSV1:=1 SET: TSV1:=0
DC_Source:=400 DEL: DT1##Dead_Time
SINE1
TRANS3
TRANS4
AMPL=Modulation_Index STATE_11_4 STATE_11_3
FREQ=Frequency -800.00
2.00 2.20 2.40 2.60 2.80 3.00
Time [ms]
TRIANG1
SET: TSV4:=0 SET: TSV4:=0
AMPL=1 DT4 SINE1.VAL > TRIANG1.VAL
SET: TSV3:=0 SET: TSV3:=1
FREQ=Carrier_Freq SET: TSV2:=0 SET: TSV2:=1
SET: TSV1:=0 SET: TSV1:=0
DEL: DT4##Dead_Time 150.00 Curve Info rms
WM1.I
TR 41.6165

250.00 Curve Info Y Axis873.02

rms 100.00 WM2.I
TR 34.8648
WM1.I
TR Y1 38.9542

WM2.I
500.00 50.00
125.00 TR Y1 34.1140

WM1.V

Y1 [A]
TR Y2 276.0822

Y1 [A]

Y2 [V]
0.00 0.00
0.00 -0.0037 WM2.V
TR Y2 316.6292
-40.2840 -53.6971
-64.8250 -315.0105 -319.5653
-408.7847 -377.1247 -50.00
-125.00 -500.00

-100.00
-250.00 -1000.00
2.900 2.925 2.950 2.975 3.000
Time [ms]
-150.00
MX1: 2.9200 0.0610 2.00 2.20 2.40 2.60 2.80 3.00
MX2: 2.9811 Time [ms]

System Level Modeling

Electromagnetic-Circuit

Wireless Power Transfer

Electromagnetics
42 © 2012 ANSYS, Inc. December 18, 2014