Optimized Design of New Coupling Mechanism for Electric Vehicles
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摘要: 针对电动汽车无线充电应用，提出了一种凹凸型磁耦合机构，在减小磁芯体积的情况下实现了更好的耦合特性，提高了系统功率传输能力. 基于有限元理论，利用COMSOL电磁场仿真软件，建立了凹凸型耦合机构的有限元仿真模型，针对线圈两端凸起磁芯高度、线圈两端凸起磁芯长度配比、磁芯长度、磁芯长度与宽度之间的约束关系以及磁芯厚度等主要结构参数从互感及耦合系数等角度分别进行了分析和优化设计，并讨论了磁芯变薄后的磁饱和特性. 通过仿真和实验测试结果验证了所设计耦合机构的可行性及在磁场分布及耦合特性方面的优势，使得系统的输出功率和效率相对原条状磁芯结构分别提高了37%和10%.Abstract: Aimed at the application of wireless charging in electric vehicles, a type of concave-convex magnetic coupling mechanism is proposed, which realizes better coupling characteristics and improves the system power transmission capacity. Based on the finite element theory and the COMSOL simulation software, a model of the concave-convex coupling mechanism was developed. According to the height of the convex magnetic core at both ends of the coil, the length ratio of the convex magnetic core at both ends of the coil, and the core length, the relationship between the length and the width of the core and the main structural parameters such as the thickness of the core was analysed and optimised from the perspective of mutual inductance and coupling coefficient, respectively. The magnetic saturation after thinning is also discussed. The feasibility of the coupled mechanism and the advantages of the magnetic field distribution and coupling characteristics were verified by the simulation and experimental results. The output power and efficiency of the system improved by 37% and 10%, respectively, compared with those of the original strip core structure.
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Key words:
- electric vehicle /
- static charging /
- concavity and convexity /
- coupling
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图 5 磁芯凹槽厚度与耦合系数的关系
Figure 5. Relationship between core groove thickness and coupling coefficient
图 6 凸出磁芯长度占比与耦合系数的关系
Figure 6. Relationship between the length of the protruding core and the coupling coefficient
图 7 磁芯长度与互感、自感及耦合系数的关系
Figure 7. Relationship between core length and mutual inductance, self-inductance and coefficient
图 9 不同长度磁芯随着磁芯宽度变化所对应的耦合系数
Figure 9. Coupling coefficient corresponding to the variation in the core width with different lengths
图 10 最优长宽配比下的Z与k的关系
Figure 10. Relationship between Z and k under the optimal aspect ratio
图 11 磁芯宽度、厚度与互感的三维曲面
Figure 11. Three-dimensional surface of the core width, thickness，and
图 12 目标函数kmax = f（
$ \!\!\!\!\!X \text{，}\!\!\!\!\!Y \text{，}\!\!\!\!\!Z$ ）的求解过程Figure 12. Solution of the objective function kmax = f（
$ \!\!\!\!\!X \text{，}\!\!\!\!\!Y \text{，}\!\!\!\!\!Z$ ）
图 13 凹处磁芯上/下表面磁感应强度的变化曲线（Ip = 23 A）
Figure 13. Variation curve of B on the upper and lower surface of concave core (Ip = 23 A)
图 14 凹处磁芯上表面磁感应强度的变化曲线（Ip = 40 A）
Figure 14. Variation curve of B on the upper cores of concave core (Ip = 40 A)
图 15 Z = 9 mm时凹处磁芯上/下表面B的变化曲线（Ip = 23 A）
Figure 15. Z = 9 mm when the surface and the bottom of the core magnetic flux density B (Ip = 23 A)
表 1 电磁耦合机构磁芯参数
Table 1. Electromagnetic coupling mechanism core parmeters
参数 原结构 新结构 参数 原结构 新结构 x/mm 279 270 f/kHz 20 20 y/mm 28 36 M/μH 96.10 115.95 z/mm 16 9 k 0.173 0.188 Vc/cm3 1 500 1 166 Rp/Ω 0.270 0.267 Ip/A 23 23 Rs/Ω 0.270 0.263 注：Vc为磁芯用量总体积；f为系统工作频率；Rp、Rs分别为原、副边线圈的阻值. 
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