Multi-Objective Optimization of 50 kW/85 kHz IPT System for Public Transport

Inductive power transfer (IPT) is an attractive solution for the automated battery charging of public transport electric vehicles (EVs) with low maintenance requirements. This paper presents the design of a 50 kW/85 kHz contactless EV charger, with a focus on the IPT transmitter and receiver coils. The multi-objective magnetics optimization reveals the Pareto tradeoffs and performance limitations in terms of high efficiency, high power density, and low stray field for high-power IPT systems without moving mechanical parts. A full-scale hardware prototype is realized and experimentally investigated. The dc-dc conversion efficiency, including all the power electronics stages, is measured as 95.8% at 50 kW power transfer across an air gap of 160 mm (coil dimensions 410 x 760 x 60 mm(3)). With 150 mm coil misalignment in the worst case direction, the dc-dc efficiency drops to 92%. The measurements of the magnetic stray field show compliance with ICNIRP 2010 at 800 mm distance from the IPT coil center.