Development of receiver antennas (secondary coils) for wireless electric vehicle charging systems, for Grupo Premo.
INNOVATION
This technology overcomes the limits of conventional ferrite cores to meet the requirements of wireless electric vehicle charging systems. The magnetic core helps improve efficiency (above 95%) by optimizing the coil.
WHAT WE DID
Andaltec’s work focused on developing the prototype of the magnetic platform, where we evaluated different design alternatives related to materials, geometry, as well as the manufacturing process of the prototype and new magnetic-polymeric materials.
THE PROJECT
Andaltec collaborated on this initiative, enabling a technology for wireless inductive power transfer in the range of 79 to 90 kHz, with a central frequency of 85 kHz. This technology overcomes the limits of conventional ferrite cores to meet the requirements of wireless electric vehicle charging systems.
Andaltec participated in the development of receiver antennas (secondary coils) for wireless electric vehicle charging systems, a project led by PREMO. These are the WC-RX series receiver antennas that offer a flexible magnetic core combining Flex-Ferrite blocks and PBM to operate with power from 3 to 11 kW.
This magnetic core technology helps improve efficiency (above 85%) by benefiting from coil optimization, which prevents air gaps and reduces hot spots. The result is a compact antenna with a high-Q factor (minimal loss) and high reliability.
The new series of receiver antennas for wireless electric vehicle charging systems aims to support wireless power transfer (WPT) inductive systems that eliminate the need for physical contact between the vehicle and the station, thereby overcoming some of the drawbacks caused by traditional conductive methods. This system becomes particularly essential for autonomous vehicles.
The challenge is to replace the conductive charging method with WPT technology while maintaining comparable power and efficiency levels. In the short to medium term, the goal is to charge electric cars while they drive on the road, automated guided vehicles (AGVs) in factories, autonomous robots, and forklifts in warehouses.
This could lead to a significant reduction in battery packs, increased range for electric vehicles, and a decrease in battery prices. The development of this series of receiver antennas (secondary coils) is the result of three years of research into the design of inductive components, applying the 3DPower concepts (for the magnetic elements involved in WPT) and ALMA (for long-range antennas with flexible magnetic cores).
This innovative equipment is the product of the completed W Alma project, focused on the development and implementation of magnetic-polymeric materials for RFID applications, aiming to combine current MnZn ferromagnetic material cores.
Andaltec’s work in this project focused on developing prototype materials for the magnetic platform, evaluating different design alternatives related to materials, geometry, and the manufacturing process of the prototype and new magnetic-polymeric materials, ensuring the prototype was optimal and cost-effective.
