Wireless Power Transfer Coupling Mechanism for Rotating Equipment
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摘要:
针对旋转轴设备传统电刷滑环供电结构复杂、接触易失效的问题，提出一种具有互感补偿功能的同轴双发射-单接收螺旋式无线传能耦合机构，以提升系统抗轴向偏移能力. 首先，基于同轴螺旋线圈互感模型，建立以抗轴向偏移为目标的双发射线圈位置优化计算方法；其次，阐述耦合机构的拓扑结构与工作原理，分析适用于旋转导向无线电能传输（WPT）系统的LCC-S补偿拓扑；通过有限元仿真与参数优化完成耦合机构设计. 实验结果表明，该耦合机构在轴向偏移40 mm时互感变化率仅为0.35%，在发生
Y 轴和Z 轴方向偏移时系统输出功率和传输效率几乎不变，明显优于传统单线圈结构；另外，系统正常传输功率12.72 W，传输效率达90.3%，轴向偏移60 mm时传输功率12.22 W，传输效率为87.0%，输出功率变化率最大为4%，传输效率仅降低3.3%. 验证了该耦合机构在旋转设备无线供电中抗偏移与高效传输的性能优势.Abstract:To address the structural complexity and susceptibility to contact failure of traditional brush-slip ring power supplies for rotating shaft equipment, a coaxial helical wireless power transfer coupling mechanism featuring two transmitters, one receiver, and a mutual inductance compensation function is proposed to improve axial misalignment tolerance. First, based on the mutual inductance model of coaxial helical coils, a calculation method for optimizing the positions of the two transmitting coils to improve axial misalignment tolerance was established. Second, the topological structure and working principle of the coupling mechanism were described, and the LCC-S compensation topology applicable to rotary steerable wireless power transfer (WPT) systems was analyzed. The coupling mechanism was designed through finite element simulation and parameter optimization. The experimental results show that the mutual inductance variation of the coupling mechanism is only 0.35% at an axial offset of 40 mm. The system output power and transmission efficiency remain almost unchanged when offsets occur along the Y- and Z-axes, demonstrating significantly better performance than the traditional single-coil structure. In addition, the system transmits 12.72 W with a transmission efficiency of 90.3% under normal operating conditions. At an axial offset of 60 mm, the transmitted power is 12.22 W, and the transmission efficiency is 87.0%. The maximum variation in output power is 4%, and the transmission efficiency decreases by only 3.3 percentage points. These results demonstrate the advantages of the proposed coupling mechanism in terms of misalignment tolerance and power transfer efficiency for the wireless power supply of rotating equipment.
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Key words:
- wireless power transfer /
- helical coil /
- misalignment tolerance /
- transmission efficiency
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图 4 互感的理论解和有限元解
Figure 4. Theoretical and finite element solutions for mutual inductance
图 8 互感值随接收线圈Z轴偏移量m1的变化曲线
Figure 8. Mutual inductance versus receiver coil Z-axis offset m1
图 19 Z轴偏移时逆变器输出电压和电流
Figure 19. Inverter output voltage and current under z-axis offset
图 20 Z轴偏移时整流器输入电压和电流
Figure 20. Rectifier input voltage and current under z-axis offset
表 1 两同轴螺旋线圈尺寸
Table 1. Dimensions of two coaxial helical coils
参数 值 参数 值 $ R/\text{mm} $ 72.5 $ {a}_{1}/\text{mm} $ 132 $ R'/\text{mm}$ 62.5 $ {a}_{2}/\text{mm} $ 66 $ {N}_{1} $/匝 66 $ m/\text{mm}$ −40 ～ 40 $ {N}_{2} $/匝 33 
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表 2 耦合线圈尺寸
Table 2. Size of coupling coil
参数 值 参数 值 $ {R}_{t}/\text{mm}$ 72.5 $ {N}_{t} $/匝 33 $ {R}_{r}/\text{mm} $ 62.5 $ {N}_{r} $/匝 66 $ r/\text{mm} $ 2
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表 3 互感变化曲线相关参数
Table 3. Parameters for mutual inductance variation curves
参数 $ {M}_{0} $ $ {M}_{{\mathrm{max}}} $ $ {M}_{{\mathrm{min}}} $ 值/μH 211.65 212.82 211.10
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表 5 仿真电路各项参数
Table 5. Simulation circuit parameters
参数 值 参数 值 参数 值 $ {R}_{1} $/Ω 0.4 $ {L}_{1} $/μH 380 $ {C}_{2} $/nF 27 $ {R}_{2} $/Ω 0.4 $ {L}_{2} $/μH 370 $ {V}_{{\mathrm{in}}} $/V 10 $ {R}_{{\mathrm{L}}} $/Ω 10 $ {C}_{{\mathrm{F}}} $/nF 50 $ f $/kHz 50 $ {L}_{{\mathrm{F}}} $/μH 200 $ {C}_{1} $/nF 59
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表 6 实验各元件参数
Table 6. Experimental component parameters
参数 值 参数 值 $ {L}_{{\mathrm{F}}} $/μH 222 $ {C}_{1} $/nF 64 $ {L}_{1} $/μH 380 $ {C}_{2} $/nF 27 $ {L}_{2} $μH 370 $ {R}_{1} $/Ω 0.7 $ {C}_{{\mathrm{F}}} $/nF 45 $ {R}_{2} $/Ω 0.8
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表 7 互感测量结果
Table 7. Mutual inductance measurement results
参数 $ {M}_{0} $ $ {M}_{{\mathrm{max}}} $ $ {M}_{{\mathrm{min}}} $ 值/μH 217.2 218.1 215.8
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表 8 实验电路参数
Table 8. Experimental circuit parameters
参数 $ {U}_{{\mathrm{S}}} $/V $ f $/kHz $ {R}_{{\mathrm{L}}} $/Ω 值 10 50 10
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表 9 电压电流有效值
Table 9. RMS values of voltage and current
参数 值 参数 值 $ {U}_{S} $/V 10 $ {U}_{2} $/V 10.4 $ {I}_{0} $/A 1.52 $ {I}_{2} $/A 1.44
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表 10 电压电流有效值
Table 10. RMS values of voltage and current
参数 值 参数 值 $ {U}_{S} $ 10V $ {U}_{2} $ 10.4V $ {I}_{0} $ 1.51A $ {I}_{2} $ 1.385A
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