Inductive Power Transfer

At Fraunhofer IISB, we are at the forefront of researching and developing inductive power transfer (IPT) technologies. Inductive power transfer enables fully contactless – wear- and spark-free – energy transmission, providing maximum operational safety. This is especially important in dusty, humid, or rotating applications where traditional connectors fail prematurely. Therefore, this technology creates added value in wide range of applications, for example:

  • Inductively dynamically powered electric vehicles (cars, vans, and even heavy-duty vehicles) with reduced battery volume/weight and transmission powers of up to 300 kW already achievable today while in motion. To put this into perspective: approximately 100 kW is required for trucks to drive continuously at 80 km/h on flat terrain without additional charging stops.
  • Inductive stationary charging of electric vehicles with power classes according to SAE J2954 from WPT1 3.6 kW, WPT2 7.2 kW, WPT3 11 kW, and WPT4 22 kW. Higher power classes for stationary systems up to the MW range are technically possible and are the subject of ongoing standardization.
  • Customized auxiliary power supplies (e.g., 48 V to 48 V or 24 V to 24 V) for applications with very high insulation requirements
  • Non-contact connectors for demanding environmental conditions
  • Power supply for moving or rotating electrical loads

Our mission at Fraunhofer IISB:

We are the independent European research institution for the development and evaluation of contactless energy transfer technologies and a driving force for new value creation.

We develop and implement complete stationary and dynamic IPT systems – from FEM simulation of the inductive transmission system to the analysis, simulation, and design of the required power electronics, through mechanical integration to the implementation and testing of fully functional demonstrators. In addition, we develop process and testing technologies for IPT systems.

Robot-assisted test bench for inductive power transfer

The robotic system performs repeatable dynamic and static tests to evaluate efficiency and power transmission in inductively coupled vehicles

With seven axes, an impressive load capacity of 170 kg at the farthest point, and a 13.5-meter-long track, the new system allows for total free movement —at a speed of 2.4 m/s.

This allows for the investigation of a wide variety of real-world scenarios relevant to inductive charging, in which the coils of the ground assembly in the road and those of the vehicle are misaligned with one another. While driving, this can occur when changing lanes, due to inaccuracies during autonomous driving, or as a result of detours, obstacles, and uneven road surfaces. Parking at an angle or at an incline at the charging points also affects power transfer. Our innovative test bench provides valuable insights into the interoperability of different coils and charging systems and sets the standard for future developments in coil design.

Q&A about inductive charging 

  • For wireless charging, coils are installed in roads or parking areas. These coils use a magnetic field to transfer electrical energy inductively to a receiver coil in the vehicle's underbody. This allows cars, buses, delivery vans, and trucks to charge while stationary or – on appropriately equipped routes – even while driving. Since no physical connection is necessary, the technology can be installed on a wide variety of areas, such as roads, parking lots, depots, or bus stops. This allows vehicles to charge "on the side," reducing long downtimes at traditional charging stations and the need for very large batteries.

    A similar principle is used for inductive charging of smartphones and also in many kitchens with induction cookers, where heat is transferred to the bottom of the pot via a magnetic field.

  • Wireless systems are flexible, discreet, low-maintenance, and also suitable for autonomous vehicles, as no manual plugging and unplugging is necessary. They can also serve as a common charging platform for entire vehicle fleets.

    In conductively charged vehicles, the contacts can wear out or become soiled. These problems do not occur with inductive charging systems. Furthermore, the vehicle does not need to be plugged in. This is a major advantage, especially for autonomous systems. A vehicle can drive to its parking space independently and charge there. No plug is necessary.

    Wireless charging while driving has further advantages: It reduces dependence on critical battery raw materials by making it possible to reduce battery sizes. In addition, vehicles are not charged at high power at rest stops, but rather draw moderate power. This stabilizes the grid and increases the overall efficiency of the system. One further efficiency advantage over conventional electric vehicles is that battery losses can be eliminated and the transmitted power can be fed directly into the motor. 

  • Inductive: Energy transfer without cables via a magnetic field. This type of energy transfer requires a transmitter and receiver coil. Examples include wireless charging of smartphones or electric toothbrushes.

    Conductive: Direct connection via plugs, rails, or current collectors. This technology requires a physical connection to the vehicle.

  • No. The coils are only switched on at the exact moment when an inductively charged vehicle drives over them. At all other times, the coils are switched off. 

  • According to SAE J2954, 85 kHz is specified for inductive energy transfer in road traffic. 

  • Yes, there are already pilot projects in various countries such as Sweden, the USA, France, and Germany. In France, there is a test section on the Autoroute A10 south of Paris, and in Germany on the A6 highway near Amberg (Bavaria). 

  • Visually, hardly at all: the induction coils are invisible, lying a few centimeters below the asphalt surface. Only inconspicuous control cabinets (so-called management units) at the roadside control the coils. On the motorway in France, these management units are installed underground and are therefore invisible. Anyone driving on the road will not notice any difference.

  • The power supply is segmented. The control cabinets (management units) are spaced 100 meters apart. This results in a maximum cable length of around 50 meters per section (between the control cabinet and the coil).

  • The system complies with the limits set by the Bundesnetzagentur (Federal Network Agency) and also meets the stricter requirements of the IEC 61980 product standard for inductive charging. These limits must also be met during dynamic operation. 

  • No. The system on the test track is only active when a suitably equipped vehicle is driving directly over the charging coils. The highest field strengths occur in the immediate vicinity of an actively charging vehicle .

    The relevant limit values are:

    • ICNIRP 2010 (EU): 27 µT
    • ANSI IEEE (US – with a focus on implant safety): 1.63 mT (= 1,630 µT)
  • The system is largely silent. Only during operation may a quiet humming sound occur in the control cabinets, similar to that of a refrigerator.

  • Yes. Stable charging performance is possible even when driving at speeds above 120 km/h. However, it should be noted that the amount of energy transferred is related to the driving time on the charging section. 

  • Yes, the system is applicable with both construction methods.

  • Yes. It can be installed almost invisibly in busy areas such as bus terminals, taxi lanes, or parking lots and enables charging even during short stops (so called “snack charging”).

  • Yes. Neither snow nor ice interfere with inductive energy transfer. The system can also be used in tunnels or on bridges. However, for reasons of cost and system optimization, the coils are not usually installed continuously in tunnel or bridge areas. 100 % coverage of a route is not necessary: vehicle batteries can easily cover unequipped sections of the route.

  • No. To use inductive charging systems, electric vehicles must be equipped with receiver coils and the required electronics. These components are necessary to pick up the electromagnetic field generated by the road module and convert it into electrical energy. 

  • Yes, but they are so far only used pilot projects and test facilities.

  • The calibration procedure and billing have not yet been finalized. However, there are ongoing funding projects (without IISB participation) that are addressing this issue.

  • Only authorized vehicles that are recognized by a contactless charging system can draw energy.

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