电动汽车无线充电磁耦合器屏蔽层的优化设计

Optimization and Design of Shielding Layer in Magnetic Coupler for Wireless Charging of Electric Vehicles

针对电动汽车车载无线充电磁耦合器体积和重量大、铁氧体易碎裂的问题,提出了一种由铁氧体磁片、纳米晶带材及铝箔构成的复合屏蔽层磁耦合器。通过Maxwell分别对铁氧体和四种纳米晶磁芯的性能进行分析和比较,在机器学习得出磁耦合器最优磁芯结构的基础上,优化设计了复合屏蔽层结构及各部分材料构成比例,与传统铁氧体磁片和铝板构成的磁耦合器相比,所提出的复合屏蔽层磁耦合器在减小了体积和重量的同时,互感和耦合系数分别提高了8.2%和0.7%,成本减小了47%。最后搭建了传输距离为12 cm的实验平台进行了验证。

To address the issues of large volume and weight of a magnetic coupler for onboard wireless charging of electric vehicles as well as the susceptibility of ferrite fragmentation,a magnetic coupler with a composite shielding layer composed of ferrite magnetic sheets,nanocrystalline strips and aluminum foil was proposed in this paper.The performances of ferrite and four types of nanocrystalline magnetic cores were analyzed and compared by Maxwell,respectively.Based on machine learning,the optimal magnetic core structure of the magnetic coupler was obtained,and the structure of composite shielding layer and material composition ratio of each part were optimized.Compared with the traditional magnetic couplers composed of ferrite magnetic sheets and aluminum plates,the volume and weight of the magnetic coupler with the proposed composite shielding layer were reduced,while its mutual inductance and coupling coefficient were improved by 8.2%and 0.7%,respectively.In addition,its cost was reduced by 47%.Finally,a 2.5 kW experimental platform with a transmission distance of 12 cm was built for verification.