Analysis of Production Influences on the Transmission Efficiency of Wireless Power Transfer Systems

Wireless power transfer (WPT) systems for electric vehicles are a more customer-friendly and convenient way of charging. Moreover, it seems to be a promising solution to increase the range of electric vehicles without having to use larger batteries. In addition to the positioning of the transmitter and receiver coils, the fabrication of the individual coils can also have a crucial impact on the overall efficiency of the transmission. The main objective of this paper is to use simulation results and practical validation to determine which manufacturing processes in the automated production of inductive power transmission systems affect both system efficiency and transmission performance for inductive charging applications. From the analysis of the process steps, the resulting manufacturing deviations are determined and evaluated. First, the manufacturing influences under real conditions are determined by performance measurements. The results obtained can be used to perform a simulative loss analysis of the components. It thus provides knowledge that can be used to design and monitor each process step.