作者:
作者单位: 1.同济大学 汽车学院，上海 201804;2.智能型新能源汽车协同创新中心，上海 201804
作者简介: 熊萌（1994—），男，博士生，主要研究方向为车载无线电能传输的磁芯优化与系统控制等。E-mail：tjuxiongmeng@qq.com
通讯作者: 魏学哲（1970—），男，教授，工学博士，主要研究方向为汽车电子及新能源汽车储能电源系统。E-mail：weixzh@tongji.edu.cn
中图分类号: O44;TM27;TN99
基金项目:
Application of Highly Saturated Flexible Nanocrystalline Core in Wireless Charging of Electric Vehicles
Author:
Affiliation: 1.School of Automotive Studies， Tongji University， Shanghai 201804， China;2.Intelligent New Energy Automotive Collaborative Innovation Center， Shanghai 201804， China
Fund Project:
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摘要:采用一种具有高饱和限值与高柔性的新型纳米晶磁芯，以解决主流Mn-Zn铁氧体磁芯在大功率应用中易磁饱和且机械性能差等问题。针对纳米晶材料电阻率小，85 kHz下涡流损耗较大，提出晶粒细化热处理工艺与交错层叠式拼接工艺来改善其涡流损耗。基于有限元仿真分析，初步验证了工艺优化的可行性，并采用4种不同磁导率的纳米晶磁芯与铁氧体磁芯对比。通过静态参数分析与7.7 kW下的效率测试与温度测试，工艺优化后的纳米晶磁芯取得显著效果。在11 kW抗饱和测试与磁泄露测试中，性能最优的DOE4纳米晶即使厚度减小到2 mm，线圈间AC-AC交流传输效率仍保持在97.408%，磁芯最高温度只有80.9 ℃，漏感完全满足ICNIRP2010限值要求。相反，铁氧体磁芯难以承受交变强磁场作用，并发生局部碎裂和过温。
Abstract:To solve the problem that the ferrite core is easy to be saturated and has a poor mechanical performance in high power applications， a novel flexible high-saturation nanocrystalline core is adopted. However， due to low resistivity， nanocrystalline has a strong eddy current in the 85 kHz alternating electromagnetic field. To reduce the eddy loss， a refinement crushing process and an alternating seamless stitching process are proposed. Based on finite element simulation analysis， the feasibility of the modified process has been preliminarily proved. Four schemes of nanocrystalline cores with different permeabilities are compared with ferrite. The static parameter analysis and 7.7kW power transfer test indicate that the modified nanocrystalline cores perform well. Moreover，the nanocrystalline core with the best performance is adopted for anti-saturation test and leakage measurement at 11kW. Even when its thickness is decreased to 2mm， the AC-AC efficiency is still 97.408%. The maximum temperature of core is only 80.9℃， and flux leakage completely meets the limit requirements of ICNIRP 2010. In contrast， the ferrite core cannot withstand the action of a strong alternating field and is broken.
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