中心开窗结构的GFSP磁耦合机构轻量化设计
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1.重庆理工大学电气与电子工程学院重庆400054; 2.重庆协美电气有限公司重庆401328

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TH162TM724

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重庆理工大学研究生教育高质量发展项目(gzlcx20243091)资助中心


Lightweight design of the GFSP magnetic coupling mechanism featuring a center-window structure
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1.School of Electrical and Electronic Engineering, Chongqing University of Technology, Chongqing 400054, China; 2.Chongqing Xeme Electric Co.,Ltd., Chongqing 401328, China

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    摘要:

    针对负载移动场景下无线电能传输(WPT)系统的轻量化与抗偏移性能的综合需求,提出了一种面向工程实现性的中心开窗结构的网格型扁平螺线管(GFSP)磁耦合机构轻量化设计方法。首先,采用GFSP线圈作为WPT系统的发射和接收机构,基于互感理论对分散绕制的耦合系数进行机理建模与分析,分析分散绕制方式在提升耦合系数方面的作用机制,并指出该结构在位置偏移工况下具有更低的互感波动性。在此基础上,对GFSP磁耦合机构的铁氧体平面中心区域进行开窗设计,并提出相应的参数设计流程以实现结构减重与耦合性能保持之间的权衡,同时给出具体的参数实例设计。随后,通过建立未轻量化设计和轻量化设计的GFSP磁耦合机构ANSYS/Maxwell仿真模型,对耦合系数保持率进行对比分析,结果表明该设计在显著减小铁氧体重量的同时,仍能在水平偏移、传输距离变化以及垂直偏转等工况下保持良好的耦合性能。最后,构建基于单管双路P#LCC-S补偿拓扑的200 W实验样机,相较未轻量化设计的原始结构磁耦合机构重量减轻25%,并在水平偏移60%、垂直偏转90°以及传输距离80~120 mm范围内开展抗偏移性能与输出稳定性测试,输出电压不低于25 V,传输效率始终不低于80%,验证了所提设计方法的有效性与工程可行性。

    Abstract:

    To address the combined requirements for lightweight design and misalignment tolerance in wireless power transfer (WPT) systems for mobile load scenarios, this article proposes an engineering-oriented lightweight design method for a grid-type flat spiral pad (GFSP) magnetic coupler with a central windowed ferrite structure. First, GFSP coils are utilized as the transmitting and receiving units of the WPT system. Based on mutual inductance theory, a mechanism model is formulated to analyze the coupling coefficient under distributed winding, revealing how the winding configuration improves the coupling performance and reduces mutual inductance fluctuation under positional offsets. On this basis, a central opening is introduced in the ferrite plane of the GFSP structure. A corresponding parameter design process is proposed to balance structural weight reduction and coupling performance retention, and a representative parameter design is provided. Then, ANSYS/Maxwell simulation models of the original and lightweight GFSP magnetic couplers are established for comparative analysis of coupling coefficient retention. Results show that the proposed design significantly reduces ferrite weight while maintaining robust coupling performance under lateral misalignment, varying transmission distances, and vertical tilt conditions. Finally, a 200 W experimental prototype based on a single-switch dual-branch P#LCC-S compensation topology is established. Compared with the original design, the magnetic coupler̓s weight is reduced by 25%. Under 60% lateral offset, 90° vertical tilt, and 80~120 mm transmission distance, the system maintains an output voltage above 25 V and transfer efficiency above 80%, evaluating the effectiveness and engineering feasibility of the proposed design.

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杨奕,郭科,夏诗蕴,李海啸,郑朝永.中心开窗结构的GFSP磁耦合机构轻量化设计[J].仪器仪表学报,2025,46(8):185-197

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  • 在线发布日期: 2025-11-07
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