Coil Parameter Analysis in Wireless Electric Vehicle Charging
KSHITIJ GHIMIRE
Master of Engineering
SRH Berlin University of Applied Sciences
Berlin
GERMANY
Abstract: - The hassle of using plug-in charging for electric vehicles (EVs) such as connecting charger to the
port of vehicles, risk of getting electrocuted during rain, dirty and oily charging cable etc. can be eliminated
using wireless/induction power transfer (IPT). It can be made smart and automated. Hence, IPT can be
considered the future of EV charging. However, the technology is just emerging and there are a lot of
limitations at present. The major problems are less efficiency caused by coil misalignment and air gap, and the
electro-magnetic field generated around the coils which possesses greater risk for human health. These can be
improved by selecting the types of coils and shields which produce maximum magnetic flux between the coils
whereas reduce the flux outside the coils. In this research, the strength of magnetic fields produced by various
types of coils (circular, square and hexagonal) were simulated in Ansys Maxwell 3D to understand their
features and to know which coil is the best for high power transfer efficiency. Similarly, the effects of using
ferrite and aluminum shields for leakage reduction, by varying their thickness, were studied. Finally, the
leakage flux values were simulated at very high currents to understand their behavior in such conditions.
Key-Words: - electric vehicle (EV), induction power transfer (IPT), coupling coefficient (k), mutual inductance
(M), magnetic flux density (B), leakage magnetic flux, airgap, coil misalignment.
Received: December 23, 2021. Revised: November 6, 2022. Accepted: December 4, 2022. Published: December 31, 2022.
1 Introduction
For wireless charging of an EV, two coils are used
at some air gap. The primary winding is positioned
on the roadway which is connected to the public
grid along with power electronics. The secondary
winding is located within the car and is connected to
y management system (BMS). When
the charging process is started, the current flows
through the primary coil, which creates a magnetic
field around the coil because of which, current is
induced in the secondary coil which recharges the
battery in the vehicle. The working of wireless
charging along with its parts are shown in the figure
below:
Fig. 1: Parts of a wireless EV charging system [1]
The charging process begins from the grid supply
which can be from renewable or non-renewable
sources. Since, the standard frequency for induction
power transfer is 85kHz (recent standard) or 20kHz
(old standard) [2], the supply of the grid must be
converted before supplying it to the coils, which can
be achieved by AC/AC frequency converter. It
converts the frequency in two stages: first the input
AC is converted to DC and again it is converted
back to AC with high frequency using inverters.
After that, both the primary and secondary
circuits need to be connected to compensating
capacitors, so that the power transfer takes place at
resonance, which ensures that the power is
transferred with maximum efficiency at long air
gaps. The compensating capacitors can be
connected in various combinations of series and
parallel to the primary and secondary circuits.
Series-series is the simplest method and most used
in EV charging. Various researchers have offered
several other compensation topologies to combine
beneficial aspects of the fundamental topologies
because of the limitations and the load requirements
of the basic ones. Researchers have even combined
inductors in the compensation circuit to enhance the
features [3].
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DOI: 10.37394/232027.2022.4.15
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E-ISSN: 2769-2507
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The transmitting and receiving coils are kept in pad
along with the shielding materials. The coils can be
of various shapes, sizes and number of turns. Mostly
the same shapes are used in both sides whereas the
number of turns, and sizes can vary. Spiral coils are
particularly of interest for electric vehicle charging
applications because they can be made in a variety
of shapes, both rectangular and circular windings,
and because of their flexibility to optimize the coil
shape [4]. Usually, the number of turns in
transmitting sides are more than that in receiving
sides because of the limitation of the space in
vehicle chassis. The number of coils used can also
be multiple which can increase the amount of power
transfer since double power can be transferred using
two sets of coils than when a single set of coils are
used [5].
Now, the AC produced through secondary coils
needs to be converted to DC to charge the battery by
using full bridge rectifiers [2]. BMS monitors and
protects the batteries by estimating its operational
state and optimizing the performance.
The controllers, connected to both primary and
secondary sides, perform the wireless
communication between the vehicle and the
charging station so that the charging process goes in
a desired way smoothly. The information like
charging requirements, power specifications, battery
percentage etc. are transferred by the secondary
controller to the primary controller, so that the
primary side can act as required.
1.1 Efficiency
The mutual inductance (M) and the magnetic
coupling coefficient (k), which vary with the air gap
and misalignment between primary and secondary
coils, are the main factors influencing the efficiency
of the power transfer. When the coils are misaligned
or the gap between the coils is increased, the value
of M will decrease and consequently k will also
decrease. This leads to higher leakage of the
inductances of coils and hence lower system
efficiency [3]
following equation:
where L1 and L2 are the self-inductances of the
primary and secondary coils respectively. Only the
flux induced in the receiver pad, "𝜙target," is useful
for EV charging. The leakage flux, "𝜙leak" causes k
to fall and consequently decreases M. The equation
k = 𝜙target/ (𝜙target+ 𝜙leak) (2)
This equation shows, the more the flux induced in
the receiving coil, the more is the value of k and
hence more efficiency. So, the charging coils must
be designed in such a way that maximum flux is
induced in the receiving coils and the minimum
amount of the flux is leaked. The values of 𝜙target
and 𝜙leak can be varied by varying the shape, size,
and number of coils, and by adding shields which in
turns varies the values of k.
1.2 Safety
Since, very high magnetic flux is leaked during the
charging process, the leakage should be controlled
within the safety limit. The International
Commission on Non-Ionizing Radiation Protection
(ICNIRP) has published the following limitations
guidelines for the safety underexposed
electromagnetic field (EMF) for the frequency range
of 3kHz to 10 MHz:
Type
Electric
field
strength
E
(V/m)
Magnetic
field
strength
H (A/m)
Magnetic
flux
density
General
Public
83
21
27
Occupational
170
80
100
Table 1: ICNIRP safety guidelines for exposed EMF
[6]
Since, very high current is used for EV charging, the
generated flux is also very high which is beyond the
safe limit set by ICNIRP. This presents one of the
major problems of IPT charging which is the risk of
human exposure to high EMF. Hence, it is crucial to
install the shield under the transmitter and above the
receiver to reduce the leakage flux. If the magnetic
field produced is not properly shielded, the magnetic
field may also interfere with the devices or other
objects, induce battery heating, and circulate current
in metallic components of the vehicle. Shielding can
be accomplished in two ways: by diverting the
magnetic flux using high-permeability materials
such as ferrite and by creating an opposing flux
using aluminum [4]. Ferrite offers a low reluctance
alternate path to the leakage flux and diverts the flux
to the targeted locations. Eddy current is induced on
the aluminum shield because of the high-frequency
magnetic field generated by the transmitter and
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E-ISSN: 2769-2507
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receiver pad, which produces its own magnetic field
in opposite direction to minimize and cancel the
magnetic field leakage [7].
2 Problem Formulation
2.1 Literature review
Wireless power transfer was experimented to run a
laptop where the power consumption was of 12
Watts. The distance between the coils was 70cm and
the efficiency of 50% was achieved [8]. A wireless
charger was designed in MATLAB/Simulink to
simulate the power transfer to find out the values of
self-inductance and mutual inductance between the
pads. The efficiency of approximately 95% was
obtained at an air gap of 25cm. It was also found
that the values of k and M increased with the
decrease in air gap and vice versa [9]. Various
topologies of coils including circular, rectangular,
double D, double D quadrature and bipolar pad were
studied to know their features, advantages and
limitations [10]. The effects of non-ferromagnetic
metal shielding on power transfer efficiency were
studied by simulation and experiment. Double
layered metal shielding by mixing ferromagnetic
and non-ferromagnetic metals was found to improve
-
to-series WPT compensation topology was designed
using MATLAB/Simulink for bidirectional power
transfer at 3.7kW and 7.7kW operating at 40kHz
and 85kHz resonating frequency and it was
successfully experimented in the lab as well [12]. A
team of scientists from the Massachusetts Institute
of Technology (MIT) revived Tesla's theories and
experiments between 2007 and 2013 to wirelessly
transmit 60 W over a 2-meter distance with a 40%
efficiency utilizing coils with a diameter of 0.6
meter [13]. Depending on the application and
requirements, several coil shapes can be used to
transfer power at desired levels. The shape and size
of the primary coils has no limitations; however, the
size of the secondary coils should be as compact as
possible because it is kept in a confined space in
EVs. Coil structures of square, rectangular,
hexagonal, and circular shape are basic and
frequently utilized for IPT applications. The effects
of the parameters of square coils on k was studied
and compared with the effects of using ferrite cores
with square coils. It was found that if optimum
parameters are used in the design, the value of k can
be increased which optimizes the wireless charging
system by increasing the efficiency of power
transfer [14]. The M and k decreased vastly with the
increase in the air gap. When the gap was
maintained between 50 to 100 mm, reasonably high
efficiency was possible. In addition, increasing the
number of turns in primary or secondary coils, while
keeping other factors the same, a high coupling
coefficient was achieved which also helped to
increase the misalignment tolerance [15]. Two
identical double D coils were used in both the
transmitting and receiving sides to find out that each
coil transmitted power independently and
simultaneously. The magnetic field of the coils did
not interfere with each other. With the use of such
multiple coils, high power transfer can be achieved
without the losses that occur in a single coil
topology [5]. A prototype was designed to transfer
10W at 86kHz power using solar power
independently without grid connection with 75%
efficiency where the number of turns in primary and
secondary coils were 22 and 10 respectively [16].
An inductive wireless charging station prototype
was successfully experimented in Thailand, which
could achieve an efficiency of 90% with the use of
Litz wire (a type of wire that has several strands of
thinner wires) in both transmitting and receiving
coils [17]. Wireless power transfer was simulated
using Ansys for various coil geometries to calculate
their efficiency, coupling coefficient and mutual
inductance. Spiral and square coils of 120mm were
used at 1A current to analyze at what distance their
effects are harmful to human exposure [18].
Aluminum plates with small mesh holes were used
for shielding in which its effects were studied by
simulating in Ansys to find out that by making such
holes the materials cost can be optimized without
creating any harmful effects. The design was found
to have made the coupling coefficient better with
maintaining the leakage flux reduction too [19].
2.2 Coils design
There has been sufficient research in the sector of
finding the mutual induction and coupling
coefficient between the coils of various parameters
and the results obtained from the experiment were
excellent. However, achieving excellent values of M
and k does not mean all the gaps in the research are
fulfilled. The next most important question is if all
the designs proposed and experimented are safe for
human exposure. There is not enough research and
knowledge in the field of generation of leakage
magnetic flux and their shielding. This paper serves
to answer those questions in detail and helps to
understand the effects of various shielding
techniques with their varying parameters.
For the analysis, simulations were carried out in
Ansys Maxwell 3D which utilizes finite element
methods for the analysis. Three coil shapes circular,
square and hexagonal were taken with the same
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parameters of cross section 1mm*1mm, start of
helix at distance of 100mm from the centre, number
of turns of 5 and the distance between the
consecutive turns of 10mm. The values of B were
simulated at 35mm, 70mm and 105mm from the
upper coils without ferrite and aluminium, with
ferrite only and with both ferrite and aluminium. For
ferrite, the thickness of 2mm, 5mm and 7mm were
used and for aluminium, thickness of 1mm, 2mm
and 5mm were used to find the optimum thickness.
The dimensions of the ferrite cores were taken as
320mm*320m, and they were kept at the distance of
6mm above and below the coils. The dimensions of
aluminium were 360mm*360mm and were placed
1mm above and below the ferrite cores. Also, ferrite
and aluminium with holes at the centre were used to
compare the effects. All these simulations were
performed with current of 10 amperes and 20
amperes. Finally, very high currents of 100A and
200A were used to understand the leakage flux
generation in high current condition. The designs of
the coil setup drawn in Ansys are shown in the
figure below:
Fig. 2: Three basic types of coils (circular, square
and hexagonal)
Fig. 3: Coils setup with ferrite and aluminum
Fig. 4: Coils setup with holes in ferrite and
aluminum
3 Problem Solution
Various plots were obtained by simulating the above
coils setup with the current of 10A and 20A. The
plots of B at 70mm from the upper coils, without
using ferrite or aluminum, when 10A current was
supplied are given in the figure below:
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Fig. 5: Plots of B for circular, square and hexagonal
coils respectively
3.1 Effects of ferrite
The maximum values of B at various distance with
and without using ferrite for 10A current are given
in the tables below:
Circular coils
Without
Ferrite
Thickness of ferrite
Distance of
plot
2mm
5mm
7mm
35mm
384
78.4
73.2
71.8
70mm
163.4
26.23
21.09
20.8
105mm
88
12.4
10.7
10.5
Between the
coils
431.4
653
701
713
Table 2: Maximum values of B for circular coils
Square coils
Without
Ferrite
Thickness of ferrite
Distance of
plot
2mm
5mm
7mm
35mm
382
112.5
105.6
105.2
70mm
167.77
44.8
39.6
39.2
105mm
88
23.35
21.5
21.1
Between the
coils
439,5
636
670
675
Table 3: Maximum values of B for square coils
Hexagonal
coils
Without
ferrite
Thickness of ferrite
Distance
of plot
2mm
5mm
7mm
35mm
384
82.12
76.2
75.8
70mm
163.78
30.4
26.07
24.7
105mm
90
14.5
13.3
13.1
Between
the coils
398.5
662
683
685
Table 4: Maximum values of B for hexagonal coils
The values of B for various coils at various
distances are shown in the above tables with various
thickness of ferrite. The maximum value of B
produced between the coils is the highest in square
that, the
The hexagonal coils have the least value of B which
70mm and 105mm, the values of B are almost the
same in all cases. After using ferrite, the leakage
flux is best reduced outside the coils and the flux
generated is best increased between the coils in case
of circular coils. When the values of B were
compared for various thickness of ferrite, we can
see that from 2mm to 5mm there is significant
improvement whereas from 5mm to 7mm there is
only slight change. Hence, it can be concluded that
5mm is the optimum value of thickness for ferrite.
Also, we can see that although use of ferrite has
limited the flux significantly in circular and
hexagonal coils, the reduction is the least in case of
square coils.
3.2 Effects of Aluminum
The plots of B were obtained for the coil designs
without and using various thickness of aluminum
along with 5mm thick ferrite. The obtained data are
given in the tables below:
Circular
coils
Without
Aluminum
Thickness of
Aluminum
Distance of
plot
1mm
2mm
5mm
35mm
73.2
61.56
58.2
57.9
70mm
21.09
19.9
18.5
18.3
105mm
10.7
9.7
9.1
9
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Table 5: Maximum values of B for circular coils
Square
coils
Without
Aluminum
Thickness of
Aluminum
Distance
of plot
1mm
2mm
5mm
35mm
105.6
102.9
100.8
100.2
70mm
39.6
39.5
39.4
39.4
105mm
21.5
21.5
21.4
21.4
Table 6: Maximum values of B for square coils
Hexagonal
coils
Without
Aluminum
Thickness of
Aluminum
Distance of
plot
1mm
2mm
5mm
35mm
76.2
70.8
65
64.7
70mm
26.07
25.2
23.5
22.8
105mm
13.3
12.9
12.5
12.1
Table 7: Maximum values of B for hexagonal coils
Aluminum was used with ferrite to study its effects.
As we can see in the above table, aluminum helps to
reduce the leakage further. Changing the thickness
from 1mm to 2mm, we can see significant
improvement whereas from 2mm to 5mm the
change is not so significant. Hence, 2mm thickness
is considered optimum. Also, we can see that in
square coils, using aluminum does not have any
significance as other coils which again proves this
type is the hardest to limit leakage flux.
3.3 Effects at 20A current
Simulations were performed to see the effects at
20A current with 5mm ferrite and 2mm aluminum.
The values obtained are given in the table below:
Types of
coils
Distance
of plot
only
coils
coils
with
ferrite
coils with
ferrite
and
aluminum
circular
35mm
733
146.5
116.4
70mm
323
42.8
37.07
105mm
176
21.46
19.35
square
35mm
763
211
201
70mm
339
77
76
105mm
176
43
42.8
hexagonal
35mm
742.6
152.5
129.8
70mm
323
48.2
46.2
105mm
180
26.6
25.2
Table 8: Maximum values of B at 20A current
When these values are compared with the values at
10A, these are approximately doubled in each case.
This proves that B is directly proportional to the
current supplied to the coils.
3.4 Effects of holes in ferrite and aluminum
The maximum values of leakage B without and with
using holes in ferrite and aluminum at 10A current
at various distances are given in the table below:
Types of coils
without hole
35mm
70mm
105mm
circular
58.2
18.5
9.1
square
100.8
39.4
21.4
hexagonal
65
23.5
12.5
with hole
35mm
70mm
105mm
circular
61.8
20
10.5
square
103.5
40.6
22.2
hexagonal
65.4
24.8
13.6
Table 9: Maximum values of B without and with
holes in ferrite and aluminum
Since, in all the plots of B, there was a zone of very
weak flux at the center because of the space in the
coils in the center, coil setups were designed with
100mm holes in ferrite and aluminum to observe
their effects. The data in the above table show that
with holes the leakage only increases slightly which
are insignificant.
3.5 Effects at high current
The final set of simulations were performed with the
supplied currents 100A and 200A, where both
ferrite cores and aluminum shields were used with
holes. The data obtained are shown in the table
below:
100A
Types of coils
distance
circular
square
hexagonal
300mm
9.984
21.12
16.052
500mm
1.727
2.919
3.745
700mm
0.414
0.801
1.234
200A
Types of coils
distance
circular
square
hexagonal
300mm
19.458
42.424
32.126
500mm
3.554
3.015
7.438
700mm
0.826
1.624
2.385
Table 10: Maximum values of B at high current
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The obtained values were compared to see if they
are within the limit guidelines set by ICNIRP. The
value of leakage B produced by circular coils is the
lowest of all in the case of circular coils whereas the
values are the highest in square coils. The values of
hexagonal coils are in between circular and square
coils. For 100A all the values are within the same
200A, only the leakage B generated by circular coils
are within the limit.
4 Conclusion
Using ferrite and aluminum the leakage flux can be
significantly reduced to limit it within the safe
value. To find the dimension of ferrite and
aluminum, the system can be simulated in Ansys to
the zone of high flux at certain distance. The length
and breadth should be decided based on the plot
obtained. Ferrite should cover the zone of maximum
B whereas aluminum can be taken slightly larger
than ferrite which could be 20-25% bigger than
ferrite so that the setup can limit the extra leakage
which ferrite only cannot prevent. If the coils have
space in the center, the ferrite cores and the
aluminum shields also can be made with holes in the
center without increasing any harmful effects of
magnetic field. This can reduce the material
required and hence minimize the cost. To find the
dimension of the hole, simulations can be carried
out to see the zone of very weak magnetic flux. In
general, as seen in the simulated plots of B in
various conditions in this research, the holes can be
made with the dimension half of the space in the
coils. With considering the safety factors, circular
types of coils are the best among all. In case when
square coils and hexagonal coils are used at high
current, extra shielding must be used which can be
thicker and bigger ferrite cores or aluminum shields.
Similarly, if anyone must go near the coils, it is
recommended to use shielding clothes. The
conclusion about the types of coils as obtained from
this research is given below:
Table 11: Features of various types of coils
4.1 Future considerations
There are other complex types of coils which need
to be researched well to find out their properties if
those are better than simpler coils. Analysis can be
done by varying the number of turns in the coils,
cross-sectional area of the coils, air gap between the
coils etc. for finding out the best option. Similarly,
use of multiple coils in transmitting and receiving
sides must be researched which can make the
charging process faster. Composite materials must
be studied if they match the required properties for
less cost than ferrite. For better shielding at very
high currents, powered shielding such as active and
reactive shielding should be considered, in which
the shields are powered such that it produces a
magnetic field in opposite direction of the leakage
flux which cancels out the leakage flux. The
materials which can produce maximum shielding
effects with minimum extra power must be found
out. Similarly, the shielding effects of such shields
can be controlled by varying its parameters such as
voltage, current, frequency etc. to produce an exact
amount of shielding effect. Future research must
focus on the process and ideas to eliminate
misalignment and air gap so that power transfer with
high efficiency is possible. One of the ways to
eliminate this problem is by making movable
transmitting or receiving pad with the help of
sensors and actuators, so that the coils align
themselves to maintain proper alignment and air gap
needed for power transfer with high efficiency.
Types of Coils
Features
Circular
Square
Hexagonal
Power Transfer
Efficiency
high
highest
moderate
Field
Distribution
uniform
non-
uniform
uniform
Leakage
Reduction by
Shielding
highest
lowest
moderate
Field Strength
high
highest
moderate
Safety at High
Current
highest
lowest
moderate
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International Journal of Electrical Engineering and Computer Science
DOI: 10.37394/232027.2022.4.15
Kshitij Ghimire
E-ISSN: 2769-2507
108
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Contribution of Individual Authors to the
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Policy)
All the literature study, simulations, and analysis
were carried solely by the author Kshitij Ghimire.
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Scientific Article or Scientific Article Itself
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performed.
Creative Commons Attribution License 4.0
(Attribution 4.0 International, CC BY 4.0)
This article is published under the terms of the
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International Journal of Electrical Engineering and Computer Science
DOI: 10.37394/232027.2022.4.15
Kshitij Ghimire
E-ISSN: 2769-2507
109
Volume 4, 2022
