WIRELESS POWER TRANSFER FOR ELECTRIC VEHICLES AMALUDDIN BIN ZAINUDDIN This Report Is Submitted In Partial Fulfillment of Requirement for the Bachelor Degree of Electronic Engineering (Computer Engineering) Fakulti Kejuruteraan Elektronik Dan Kejuruteraan Computer Universiti Teknikal Malaysia Melaka June 2015
ii UNIVERSTI TEKNIKAL MALAYSIA MELAKA FAKULTI KEJURUTERAAN ELEKTRONIK DAN KEJURUTERAAN KOMPUTER BORANG PENGESAHAN STATUS LAPORAN PROJEK SARJANA MUDA II Tajuk Projek : WIRELESS POWER TRANSFER FOR ELECTRIC VEHICLES Sesi Pengajian : 1 4 / 1 5 Saya AMALUDDIN BIN ZAINUDDIN (HURUF BESAR) mengaku membenarkan Laporan Projek Sarjana Muda ini disimpan di Perpustakaan dengan syaratsyarat kegunaan seperti berikut: 1. Laporan adalah hakmilik Universiti Teknikal Malaysia Melaka. 2. Perpustakaan dibenarkan membuat salinan untuk tujuan pengajian sahaja. 3. Perpustakaan dibenarkan membuat salinan laporan ini sebagai bahan pertukaran antara institusi pengajian tinggi. 4. Sila tandakan ( ) : SULIT* *(Mengandungi maklumat yang berdarjah keselamatan atau kepentingan Malaysia seperti yang termaktub di dalam AKTA RAHSIA RASMI 1972) TERHAD** **(Mengandungi maklumat terhad yang telah ditentukan oleh organisasi/badan di mana penyelidikan dijalankan) TIDAK TERHAD Disahkan oleh: (TANDATANGAN PENULIS) (COP DAN TANDATANGAN PENYELIA) Tarikh : 12 JUN 2015 Tarikh : 12 JUN 2015 Tarikh:.. Tarikh:..
iii I declare this report in my own work except for summary and quotes that I have mentioned its sources Singnature : Author s Name : AMALUDDIN BIN ZAINUDDIN Date : 12 JUNE 2015
iv I hereby declare that I have read this report and in my opinion this report is sufficient in terms of the scope and quality for the award of Bachelor of Electronic Engineering (Computer Engineering) With Honours Signature : Supervisor Name : DR NORIHAN BINTI ABDUL HAMID Date : 12 JUNE 2015
v Dedicated to My Beloved Parents, Zainuddin Bin Mah Jilis and Rohaya Binti Alias, My supportive supervisor, Dr Norihan Binti Abdul Hamid My lovely siblings, My friends who have encouraged, guided and inspired me throughout my education journey
vi ACKNOWLEDGEMENT First of all, I would like to take this opportunity to express my deepest gratitude to my project supervisor, Dr Norihan Binti Abdul Hamid for her guidance, encouragement and endurance the whole course of this project. It is indeed my pleasure for her support, invaluable advices and enthusiastic toward my project. Your advice on both research as well as on my career have been priceless. My special gratitude is to my beloved family, especially my parents Zainuddin Bin Mah Jilis and Rohaya Binti Alias for their fullest support throughout the year study in Technical University Malaysia Melaka (UTeM). Because of them, I am the person who I am today, for all their moral support all these while so that I will be to complete project successfully. Not forget for my brother, Ahmad Anwar Bin Zainuddin for his guidance in completing this project. Last but not least, I would like to give a bunch of thanks to everyone especially to all my friends who involved directly and indirectly in this project. The encouragement and support given towards me earning my experience and knowledge are indescribable and without them, this project and this report would have been impossible.
vii ABSTRACT This project is a development of a new approach to charging battery for electric vehicles using the inductive resonance coupling method. Inductive resonance coupling is a combination of inductive coupling and resonance frequency produced by the alternator. The aim of this project is focused on producing suitable power of the receiver coil to charge electric vehicle s battery. This project is start through designed and simulation circuit testing, then the data are collected and analyzed. The device is develop and presented in prototype. The performance of the charging device is analyzed. The demonstration of electric car prototype can be charged wirelessly using receiver coil placed under the car and the transmitter coil on the surface on the ground. However, the prototype are not able to charge the battery of electric vehicle but power produced are able to charge any low voltage electronic device such as a smartphone and rechargeable battery.
viii ABSTRAK Projek ini memperkenalkan pendekatan baharu untuk mengecas bateri kenderaan elektrik dengan menggunakan kaedah gandingan resonans induktif. Gandingan resonans induktif adalah gabungan antara gandingan induktif dan frekuensi resonans yang dihasilkan oleh alternator. Matlamat projek ini difokuskan untuk menghasilkan kuasa yang sesuai untuk mengecas bateri kenderaan elektrik menggunakan teknologi tanpa wayar. Projek ini bermula melalui percubaan rekaan litar simulasi dan hasil dapatan kajian ini dikumpul dan dianalisa. Peranti yang dihasilkan dan dipersembahkan dalam bentuk prototaip. Kemudian, prestasi peranti pengecasan ini dianalisa. Demonstrasi prototaip kenderaan elektrik yang menggunakan pengecasan tanpa wayar dengan menggunakan gegelung penerima dipasang di bawah kereta dan gegelung penerima di atas permukaan jalan. Walaupun prototaip ini tidak mampu untuk mengecas kenderaan elektrik sebenar, kuasa yang dipindahkan mampu untuk mengecas peranti bervoltan rendah seperti telefon pintar dan bateri dicas semula.
ix TABLE OF CONTENTS CHAPTER TITLE PAGE PROJECT TITLE REPORT STATUS VERIFICATION FORM DECLARATION SUPERVISOR DECLARATION DEDICATION ACKNOWLEDGEMENT ABSTRACT ABSTRAK TABLE OF CONTENT LIST OF TABLES LIST OF FIGURES LIST OF APPENDICES I II III VI V VI VII VIII IX XIII XIV XVII I INTRODUCTION 1.1 Introduction 1 1.2 Problem Statement 3 1.3 Objectives 4 1.4 Scope of projects 4 1.5 Thesis Outline 5
x II LITERATURE REVIEW 2.1 Introduction 6 2.2 Wireless Power Transfer Principle 7 2.2.1 Microwave Principle 7 2.2.2 Laser Principle 9 2.2.3 Inductive Resonant Coupling Principle 10 2.2.3.1 Concept of Electromagnetism 11 2.2.3.2 Electromagnetic Induction 12 2.2.3.3 Resonance Frequency 14 2.2.3.4 Definition of Inductor 15 2.3 Comparison of three Principle In Wireless Power Transfer 16 2.4 Chapter Summary 18 III RESEARCH METHODOLOGY 3.1 Introduction 19 3.2 Electric Vehicle Charging System 20 3.2.1 Circuit Diagram 21 3.3 Methodology and Project Development 22 3.3.1 Methodology Flowchart 23 3.3.2 Circuit Design 25 3.3.3 Simulation and Analysis Circuit on Breadboard 26 3.3.4 Transistor and Receiver coil 27
xi 3.3.5 Printed Circuit Board (PCB) Development 3.3.5.1 Layout Design 29 3.3.5.2 Etching Process 30 3.3.5.3 Soldering Process 30 3.3.5.4 Traoubleshooting 30 3.4 Electric Vehicle Prototype Development 31 3.5 Charging Indicator 32 3.6 Component and Device used in Designed Circuit 33 3.7 Chapter Summary 36 IV RESULT AND DISCUSSION 4.1 Introduction 37 4.2 Inductance and Capacitance Value Consideration 38 4.3 Experimental Set Up 40 4.4 Result and Analysis 41 4.4.1 Correlation between distances of transmitter Circuit and receiver circuit 41 4.4.2 Correlation between of input power (via transmitter circuit) and output power (via receiver circuit) in fixed distance of 0 cm 44 4.4.3 Correlation between of input power (via transmitter circuit) and output power (via receiver circuit) in fixed distance of 5 cm 47
xii 4.4.4 Correlation between of input power (via transmitter circuit) and output power (via receiver circuit) in fixed distance of 10 cm 48 4.4.5 Relationship between of input power (via transmitter circuit) and output power (via receiver circuit) in fixed distance of 15 cm 49 4.5 Prototype 50 4.6 Prototype with a different obstacle between transmitter coil and receiver coil 51 4.7 Result of the circuit prototype demonstration 53 4.8 Electric Vehicle Prototype 54 4.9 Charging Indicator 55 4.10 Chapter Summary 56 VI CONCLUSION AND RECOMMENDATION 5.1 Conclusion 57 5.2 Recommendation 59 REFERENCES 60 APPENDICES 62
xiii LIST OF TABLES TABLE TITLE PAGE 2.1 Comparison of advantage and disadvantage of three 16 wireless power transfer method
xiv LIST OF FIGURES FIGURE TITLE PAGE 1.1 Example of electric car using plug in cable 3 2.1 Block Diagram of Microwave System 8 2.2 Magnetic field around the wire/conductor 12 2.3 Transformer 13 3.1 Block diagram of the system 20 3.2 Schematic design of transmitter circuit 21 3.3 Schematic design of receiver circuit 21 3.4 Methodology flowchart 23 3.5 Methodology flowchart 24 3.6 Circuit testing using breadboard 26 3.7 Circuit tested using multimeter to check functionality 26 3.8 Transmitter and Receiver coil manufacturing 28 (Multilayer air core Inductor) 3.9 Layout design of transmitter circuit 29 3.10 Layout design of receiver circuit 29 3.11 Acrylic sheet 31 3.12 Toy s tyre 31
xv 3.13 Charger module with rechargeable battery 31 3.14 Schematic of LCD Circuit Diagram 32 3.15 MAX17043 Fuel Gauge 33 3.16 Toroidal core inductor 34 3.17 IRFZ44N Power MOSFET 35 3.18 Enameled Cooper Wire 35 4.1 Frequency produced by an oscillator 38 4.2 Completed prototype model of wireless 40 power transfer system 4.3 Relationship between output voltages (V) and 41 output current (ma) versus distance 4.4 Relationship between output power (W) and 42 output current (ma) versus distance 4.5 Relationship between output voltages (V) and 44 output current (ma) versus input voltage (V) 4.6 Relationship between input voltages (V) versus 46 efficiency, ŋ % at the distance of 0 cm 4.7 Relationship between output voltages (V) and 47 current (ma) versus input voltage (V) at the distance of 5 cm 4.8 Relationship between output voltages (V) and c 48 urrent (ma) versus Input Voltage (V) at the distance of 10 cm 4.9 Relationship between input voltages (V) and 49 current (ma) versus input voltage (V) at the distance of 15 cm
xvi 4.10 LED light up brightly when the coil is closer 50 4.11 LED dim slightly when the coil is far each other 50 4.12 A pack of soil 51 4.13 A pack of water 51 4.14 Thick book 51 4.15 Correlation between output voltages with 52 different barrier versus distance 4.16 The output of receiver can be used as charger 53 of smartphone 4.17 An electric vehicle prototype integrated with 54 wireless power transfer device 4.18 Charging indicator to show the charging percentage 55 of the battery
xvii LIST OF APPENDICES NO TITLE PAGE A Table of Collected Data 62 G Source Code of Charging Indicator 68 H INOTEK Poster 70
CHAPTER 1 INTRODUCTION 1.1 Introduction Electricity is a necessity of today modern life. It is difficult to live or passing a day without electricity. Today, wireless power transfer has been attracting a great deal of attention. Wireless power transfer is the transmission of electrical energy from a power source to an electrical load without interconnecting wires. It is used to power on the electrical devices without the wire. Besides, because of this wireless power, some of the devices will not require the battery to operate.
2 There is a demand for wireless power transfer system. Nowadays, the development of wireless charging for smartphone is rapidly increase in market. The drawbacks of the system is the smartphone are need to attach charging plate but cannot lift it while charging. In this project, the proposed wireless power transfer technique based on inductive resonance coupling method. When AC power has been supplied through a coil, magnetic field will be generated around the coil. At the moment, if another coil put aside it, induced current will produced and caused the magnetic field will also appear around the other coil. This is the reason that wireless power transfer is set up between two coils. Energy will be transfer when both coils will have same resonant frequency. Many of the contactless feed systems are based on the electromagnetic induction s principle. Small distance wireless power transfer is demonstrated through used of induction. Knowledge of electric circuit logic and electromagnetic theory is important to realize the practical design. Knowledge of electric circuit logic and electromagnetic theory is important to realize the practical design. This project provides a literature review of several wireless power transfer principle. All the methods that have been used to design wireless power transfer will be reviewed along with advantage and disadvantage of each principle. This project will conclude a discussion to choose suitable principle to charge electric vehicle.
3 1.2 Problem Statement Current technologies only allow electric vehicles to be charged through plug-in cable. However, the problem occurs when the user need to find the charging point and the charging cable is lost or damaged. This project is about designing a wireless power transfer for electric vehicles. The concept of this project is suitable for any electric vehicles such as bus, car and light train. It will prepare a new convenient way to recharge the battery of the electric vehicles rather than using the traditional plug-in cable. With the implementation of wireless power transfer (WPT) in order to charge the electric vehicle, there is no physical connection or contact between the vehicles and the power supply. The process is fully automated, whereby no human handling works are required to perform the charging process. Even though wireless power transfer concept is well developed and has been applied in industrial application, but its applications in the transport sector are still emerging. Furthermore, another serious problem occurred with current plug in cable for electric vehicles is people tend to get an electrical shock if the cable system is damaged. With wireless charging approach for electric vehicle can prevent this incident happen because no wire or cable is required and it s transfer in electromagnetic form, so that, people will not get electrical shock in this kind of energy transfer. Figure 1.1: Example of electric car using plug in cable
4 1.3 Objectives The objectives of this project is: To study and investigate on wireless power transfer. A technique used in my research is an inductive resonance coupling method. To identify how many power (voltage and current) could transmit from primary coil (source) to a secondary coil (load). To design the wireless power transfer for electric vehicles by using the concept of inductive resonance coupling method. To prove it, a prototype will be built. 1.4 Scope of project This research focus on developing a new approach of electrical charging using wireless power transfer. Study about wireless power transmission using the inductive resonance coupling method. Implement the receiver and transmission circuit simulation into the prototype. Develop the electric vehicles wireless power transfer devices. Develop the charging indicator using LCD display. Analyze the prototype through functionality measurement and testing.
5 1.5 Thesis Outline This outline is divided into five chapters to provide reader to understand the whole project. It is organized as follows: Chapter 1, Introduction, covers the overview of the project. Chapter 2, Literature Review and Background Studies, all the project theory, perspective, methods that used to solve problem and any hypothesis that related in order to design the appropriate circuit. Chapter 3, Research Methodology, the proper procedure in designing and manufacturing of the system is presented. Chapter 4, Result and Discussion, the result of all experiments is presented. The experimental result is discussed and analyzed for future improvement. Chapter 6, Conclusions and Recommendations, the conclusions of the experimental result is drawn and future work is recommended.
CHAPTER 2 LITERATURE REVIEW 2.1 Introduction This chapter encompasses the study of existing research related to the project. Every information extracted will be analyzed to enhance the understanding of the main concept all the way through this project. There are three principle used in wireless power transfer which is microwave, laser and inductive resonance coupling principle. The fundamental of these method are analyzed and compared in terms of performance. The suitable principle will be chosen to design wireless charging for electric vehicle.
7 2.2 Wireless Power Transfer Principle The wireless power transfer is a technology of no wire included in terms of transfer the energy. Concept of wireless power transfer has been discovered widely since Nikola Tesla carried out his first experiment about pursuing his idea on wireless lighting and electrical distribution after successfully invent an alternating current [1]. They are many methods used in the wireless power transfer which are microwave, laser, and inductive resonance coupling method. 2.2.1 Microwave Principle Wireless power transfer by using microwave method has been used more than a century [1]. It is called as microwave because the characteristics itself which is shorter wavelength of electromagnetic radiation in microwave range. The limitation of the wavelength radio is difficult to tune and overall efficiency would be too low for practical use [1]. The signal transmitted by microwave method will be received by rectenna. Rectenna is a combination of rectifier and antenna is used to convert the microwave energy back into electricity. The first rectenna is developed by W. Brown, the pioneer in wireless power transfer technology in 196.The concept of microwave method is explained with block diagram shown in figure below [5].