CONTACTLESS POWER TRANSFER SYSTEM

A PROJECT REPORT

Submitted by

A. MOHAMMED HUSSAIN
S. NARENDRAN
SYED ADIL BAHAMANI

in partial fulfillment for the award of the degree

Of

BACHELOR OF ENGINEERING
in

ELECTRONICS AND COMMUNICATION ENGINEERING

TAGORE ENGINEERING COLLEGE

ANNA UNIVERSITY: CHENNAI 600 025

MAY 2011
ABSTRACT:

This paper proposes a model of Contactless Power Transfer system

(CPTS), which adopts transformer with big air-gap and primary and

secondary coils. The system has the characteristics of long leakage

inductance, small magnetizing inductance and low coupling coefficient.

This makes the transmission efficiency very low, this model improves the

system efficiency by adopting resonance of compensation capacitance

and leakage inductance in transferring energy to the load. Thus the main

objective of the project is to transfer the power without any contact.

Keyword – Contactless Power Transfer System (CPTS)

 CHAPTER 1
INTRODUCTION

1.1 INDUCTIVE POWER SUPPLY

Inductive Power Supply is a new technology which is advantageous in
comparison to current-rails, cables and battery supply systems. The advantages of this new
developed technology are based on maintenance-free operation, no sparkling effects due to
contact problems, complete isolation of primary and secondary conductors and ruggedness
against dust and environmental conditions.

The inductive power supply is based on the principle of basic transformer,

which consists of a primary windings and secondary windings. But the only difference when
compared to transformer is these two windings are separated over a distance.

In normal transformer the power is transformed in frequency ranging 50-60

Hz, but this power frequency is not enough to transfer the power over a distance between
primary and secondary coils. So we need to increase the power frequency in the range of
KHz to achieve this power transfer.

This inductive power technology can be used for transport purposes like cars, buses,
trains as mentioned. Implementing and maintenance is easy and simple. Accessing of
multiple devices and vehicles are possible since the secondary coil is placed inside the each
vehicle so it gets the power from one primary winding.

The basis for this new developed technology is the use of a primary coil and
secondary coil, but the secondary coil is located on the moving transportation system
inductively coupled to a primary winding which is located and fixed along the track of the
transportation system.

There are a number of technical criteria to be solved to make this contactless

inductive power supply working with high efficiency and to become an economically power
supply system.
 The use of high frequency leads to acceptable dimensions of the active secondary
coil. The distributed winding on the primary leads to a large impedance and therefore
corresponding apparent power is required. The effect of specific compensating technologies
is that only real power has to be supplied by the high frequency power supply on the primary.

In addition special attention has to be given to the design of the secondary coil
arrangement to provide the magnetization of the air gap between primary winding and
secondary coil. The different design aspects of contact-less inductive power supply will be
presented.
 CHAPTER 2

CONTACTLESS POWER TRANSFER

2.1 PRINCIPLE OF OPERATION

IPT is a contactless power transfer system that allows electrical energy to be supplied
to mobile equipment without any mechanical contact. Each system is comprised of two parts,
the primary and secondary. These are magnetically coupled, similar to a conventional
transformer.

The primary consists of a track power supply and track cable along the path of
electrification. The pickups and pickup regulators form the secondary. Unlike a conventional
transformer, where primary and secondary are tightly coupled, IPT is a loosely coupled
system. With higher operating frequencies (10 kHz to 25 kHz, power may be transferred
across air gaps of up to several centimeters.

2.2 BASIC BLOCK DIAGRAM

Here the system works based on the principle of transformer Power supply given to
the primary coil is at high freq which is in the range of kHz. But in this system there is a big
air gap between primary and secondary coils.

M Hu

Microcontroll
er
Cpts Cpts Load
(pwm) primary section
Secondary section

Figure 2.1 Basic Block Diagram of Contactless Power Transfer

 Hence power supply given to the primary coil is at high freq which is in the range of
kHz. The primary coil links the secondary coil through the magnetic flux of lines due to the
high freq oscillations. The primary coil links the secondary coil through the magnetic flux of
lines as shown in Figure 2.1 due to the high freq oscillations .Thus it makes to induce current
in secondary coil that is given to load.

2.3 MAIN BLOCK DIAGRAM OF CPTS

The primary section and secondary section blocks are elaborated in the below shown
Figure 2.2.The primary section consist of microcontroller, MOSFET, and resonant converter
and the secondary section consist of inductor, rectifier, filter capacitor ,boost converter
,voltage regulator, battery charger, sensor and motor.

Magnetic Coupling
across air gap

(PWM ) MOSFET Resona

nt Secondar
microcontroll
y
er Convert Induct

R
ectifier

Train Volta Boost Filter

Moto ge convert Capacit
r er or

Batter
y

Charg

Figure 2.2 Main Block Diagram of CPTS

 CHAPTER 3
CPTS PRIMARY SECTION

3.1 BLOCKS OF PRIMARY SECTION

The primary section has three main blocks

1. Microcontroller(Pulse Width Modulation)

2. MOSFET

3. Resonant converter

3.2 Microcontroller Advanced Kit - Pulse Width Modulation

It is easy to use a microcontroller to turn LEDs ON and OFF . But you can only turn
the LED ON and OFF. So what if you want to control the brightness of the LED? The same
problem comes up in robotics where you want to control the speed of a motor with a
microcontroller. It is not good enough to just turn the motor ON and OFF. To control the
brightness of the LED or speed of the motor you have to control the amount of current going
through the device. But how? One solution that may occur to you is to quickly turn the LED
or motor ON and OFF. The current only flows when the output is low (for microcontrollers
LED circuits are usually wired so current flows into the microcontroller when the output is
low, as shown in the tutorial at http://www.iguanalabs.com/1st2051.htm). The output of your
microcontroller will look like the following square wave as in Figure 3.2.1.

Figure 3.2.1 Output of Microcontroller

 If you turn an LED or motor ON and OFF fast enough then it will appear to stay on
continuously and since there is less current flowing overall the LED will appear less bright
and the motor will run at a slower speed. With this solution you can make the LED flash ON
and OFF as slow as 30 times a second but any slower and you start to see the LED blinking
which is not the desired result. Or, for the motor, it will lose its smooth operation and get
jerky. The solution does not work very well because the LED is still rather bright at 30 times
a second.

We are on the right track but rather than changing the number of times the output
goes ON and OFF, we change how long the output stays ON and OFF. Let's take a closer
look at one output cycle. An output cycle consists of a low period, tlow and a high period,
thigh. tlow + thigh = T, where T is the period (length of time) for one output cycle as in
Figure 3.2.2. thigh is also called an output pulse, or just pulse.

Figure 3.2.2 One Output Cycle

We will always keep T the same so that there is always the same number of output
cycles per second. If we increase the width of thigh then we must decrease tlow to keep T the
same. If we decrease thigh then we must increase tlow. For the case that we make thigh small
then the output looks as Figure 3.2.3 .

Figure 3.2.3 LED is ON for Long Time

 For the case that we make thigh large then the output looks like the following Figure
3.2.4.

Figure 3.2.4 LED is OFF for Long Time

The output is Vcc most of the time which turns off the LED. The current only flows
through the LED for the brief time that the LED is on during tlow. But since we are still
turning the LED on and off very fast (we will use about 100 times a second in the examples
below), you cannot see the LED blinking and it appears very dim. The total current that flows
through the LED is low. For the motor it will smoothly turn at a low speed. So we can
control the brightness of the LED or the speed of a motor by changing the width of thigh.
This is the secret of Pulse Width Modulation.

3.2.1 HOW IT WORK WITH MICROCONTROLLER

Next we will see how to make this work in an 8051. We can use the hardware setup as
shown in either the first microcontroller project for the 8051. The software examples work
for either of the hardware setups..

In the first This we uses two delay routines. One delay is used to control tlow and the
other delay is used to control thigh. The example is set to minimize tlow and maximize thigh
to make the LED appear very dim. To make the LED brighter you can decrease R4 and
increase R3. This example works fine and shows an easy way to control the pulse width. The
biggest disadvantage is that it assumes you will be not be doing anything else in your
program. If you try to do some other processing you will affect the timing of the pulses.
 And the second example uses one of the microcontrollers built in timers to control the
pulse width. A timer can be used to create delay routines while the processor is free to run
other parts of your program. It is an independent piece of hardware that you assign a task to
and it goes off and does its work without using the main processor. When it finishes its task it
lets you know by generating an interrupt. You can then give it another task and get back to
the other processing you were doing.

3.3 MOSFET

• 80-100 volts for DC to DC converter

• High current
• Ultra fast switching
• Easy drive for reduced cost and size

The metal–oxide–semiconductor field-effect transistor (MOSFET, MOS-FET, or

MOS FET) is a device used for amplifying or ultra high switching electronic signals. It is a
special type of J-FET. It is a voltage controlled device. The oscillations generated by the
CONTROLLER is not sufficient to link the secondary coil across the air gap. To increase the
oscillations we use MOSFET which is ideal for high speed switching.

3.4 RESONANT CONVERTER

The PWM generated by the microcontroller is not enough to link this circuit so we
use the MOSFET for high speed switching. The output of MOSFET will make the windings
of the primary section to get ON and OFF continuously and fast which produces flux in the
primary coil. And this flux will make the secondary coil to get induced and produce current
in the secondary section. The resonant circuit consist of iron core inductor with more number
of windings. And this flux will make the secondary coil to get induced and produce current in
the secondary section.
3.5 CIRCUIT DIAGRAM OF CPTS PRIMARY SIDE

The circuit diagram of the Power Transfer primary section is shown in the figure 3.5
below

In the above circuit diagram the microcontroller used is AT89c51 where two NOT gate
741s14 act as a driver , and two MOSFET drivers are used to control the MOSFET which is used
for speed switching. And the features and description of each component in primary side is
elaborated below.
3.5.1 8-BIT MICROCONTROLLER (AT89C51)
Features

• Compatible with MCS-51 Products ™

• 4K Bytes of In-System Reprogrammable Flash Memory
– Endurance: 1,000 Write/Erase Cycles
• Fully Static Operation: 0 Hz to 24 MHz
• Three-level Program Memory Lock
• 128 x 8-bit Internal RAM
• 32 Programmable I/O Lines
• Two 16-bit Timer/Counters
• Six Interrupt Sources
• Programmable Serial Channel

Description

The AT89C51 is a low-power, high-performance CMOS 8-bit microcomputer with

4Kbytes of Flash programmable and erasable read only memory (PEROM). The device is
manufactured using Atmel’s high-density nonvolatile memory technology and is compatible with
the industry-standard MCS-51 instruction set and pinout. The on-chip Flash allows the program
memory to be reprogrammed in-system or by a conventional nonvolatile memory programmer.
By combining a versatile 8-bit CPU with Flash on a monolithic chip, the Atmel AT89C51 is a
powerful microcomputer which provides a highly-flexible and cost-effective solution to many
embedded control applications. The AT89C51 provides the following standard features: 4K
bytes of Flash, 128 bytes of RAM, 32 I/O lines, two 16-bit timer/counters, a five vector two-level
interrupt architecture, a full duplex serial port, on-chip oscillator and clock circuitry. In addition,
the AT89C51 is designed with static logic for operation down to zero frequency and supports
two software selectable power saving modes. The Idle Mode stops the CPU while allowing the
RAM, timer/counters, serial port and interrupt system to continue functioning. The Power-down
Mode saves the RAM contents but freezes the oscillator disabling all other chip functions until
the next hardware resets.
Pin Diagram

Figure 3.5.1.1 pin diagram of microcontroller AT89C51

The above figure 3.5.1.1 shows the pin diagram of microcontroller AT89C51. Where it
has 40 pins ,in which it has three ports namely port1 (P1.0-P1.7), port(P2.0-2.7), port(P3.0-3.7).
Port 1

Port 1 is an 8-bit bi-directional I/O port with internal pullups. The Port 1 output buffers
can sink/source four TTL inputs. When 1s are written to Port 1 pins they are pulled high by the
internal pullups and can be used as inputs. As inputs, Port 1 pins that are externally being pulled
low will source current (IIL) because of the internal pullups. Port 1 also receives the low-order
address bytes during Flash programming and verification.
Port 2

Port 2 is an 8-bit bi-directional I/O port with internal pullups. The Port 2 output buffers
can sink/source four TTL inputs. When 1s are written to Port 2 pins they are pulled high by the
internal pullups and can be sed as inputs. As inputs, Port 2 pins that are externally being pulled
low will source current (IIL) because of the internal pullups. Port 2 emits the high-order address
byte during fetches from external program memory and during accesses to external data memory
that use 16-bit addresses (MOVX @ DPTR). In this application, it uses strong internal pullups
when emitting 1s. During accesses to external data memory that use 8-bit addresses (MOVX @
RI), Port 2 emits the contents of the P2 Special Function Register.
Port 2 also receives the high-order address bits and some control signals during Flash
programming and verification.

Port 3

Port 3 is an 8-bit bi-directional I/O port with internal pullups. The Port 3 output buffers
can sink/source four TTL inputs. When 1s are written to Port 3 pins they are pulled high by the
internal pullups and can be used as inputs. As inputs, Port 3 pins that are externally being pulled
low will source current (IIL) because of the pullups.

Pin Description
Table 3.1 pin description of AT89C51
Pin Number Description
1-8 P1.0 - P1.7 - Port 1
9 RST - Reset
10-17 P3.0 - P3.7 - Port 3
18 XTAL2 - Crystal
19 XTAL1 - Crystal
20 GND - Ground
21-28 P2.0 - P2.7 - Port 2
29 PSEN - Program Store Enable
30 ALE - Address Latch Enable
31 EA - External Access Enable
32-39 P0.7 - P0.1 - Port 0
40 Vcc - Positive Power Supply

Thus the pin description of microcontroller AT89C51 is show in the above tabular
column 3.1.
3.5.2 HEX SCHMITT-TRIGGER INVERTERS (74LS14)
Features

• Operation From Very Slow Edges

• Improved Line-Receiving Characteristics
• High Noise Immunity

Description

Each circuit functions as an inverter, but because of the Schmitt action, it has different
input threshold levels for positive-going (VT+) and negative-going (VT–) signals. These circuits
are temperature compensated and can be triggered from the slowest of input ramps and still give
clean, jitter-free output signals.

Pin diagram

Figure 3.5.2.1 pin diagram of IC 7414

The pin diagram of inverter IC 7414 used is shown in the above figure 3.5.2.1.
These circuits are temperature compensated and can be triggered from the slowest of input ramps
and still give clean, jitter-free output signals.
3.5.3 HALF-BRIDGE DRIVER (IR2111)

Features

• Floating channel designed for bootstrap operation

• Fully operational to +600V
• Tolerant to negative transient voltage
• dV/dt immune
• Gate drive supply range from 10 to 20V
• Under voltage lockout for both channels
• CMOS Schmitt-triggered inputs with pull-down
• Matched propagation delay for both channels
• Internally set dead time
• High side output in phase with input

Description

The IR2111(S) is a high voltage, high speed power MOSFET and IGBT driver with
dependent high and low side referenced output channels designed for half bridge applications.
Proprietary HVIC and latch immune CMOS technologies enable ruggedized monolithic
construction. Logic input is compatible with standard CMOS outputs. The output drivers feature
a high pulse current buffer stage designed for minimum driver cross-conduction. Internal dead
time is provided to avoid shoot-through in the output half-bridge. The floating channel can be
used to drive an N-channel power MOSFET or IGBT in the high side configuration which
operates up to 600 volts
 CHAPTER 4
CPTS SECONDARY SECTION

4.1 BLOCKS OF PRIMARY SECTION

The primary section has three main blocks

1. Secondary Inductor

2. Rectifier

3. Boost Converter

4. Voltage Regulator

5. Train Motor

6. Battery

4.1.1 CIRCUIT DIAGRAM OF CPTS SECONDARY SIDE

The circuit diagram of the Power Transfer primary section is shown in the figure 4.1
below
4.2 Very Fast Soft – Recovery Avalanche Rectifier (BYV26)

Features

• Glass passivated junction

• Hermetically sealed package
• Very low switching losses
• Low reverse current
• High reverse voltage

Applications

• Switched mode power supplies

• High–frequency inverter circuits
Descriptions
Diode, ultrafast, 1a, 1000v; diode type:soft recovery; voltage, vrrm:1000v; current, if
av:1a; current, ifsm:30a; time, trr typ:75ns; voltage, vf max:2.5v; temperature, tj max:175°c;
termination type:axial leaded; operating temperature range:-55°c to +175°c; case style:sod-57;
no. of pins:2; current, ifs max:30a; external diameter:3.8mm; external length / height:4.6mm;
forward voltage:2.5v; time, trr max:75ns

Figure 4.2.1 rectifier (BYV26)

Terminals: Plated axial leads, solderable per MIL-STD-750, Method 2026

Polarity: Color band denotes cathode end
Weight: approx. 369 mg
4.3 3-Terminal 1A Positive Voltage Regulator (7809)

Features
• Output Current up to 1A
• Output Voltages of 5, 6, 8, 9, 10, 12, 15, 18, 24V
• Thermal Overload Protection
• Short Circuit Protection
• Output Transistor Safe Operating Area Protection

Description

The KA78XX/KA78XXA series of three-terminal positive regulator are available in the

TO-220/D-PAK package and with several fixed output voltages, making them useful in a wide
range of applications. Each type employs internal current limiting, thermal shut down and safe
operating area protection, making it essentially indestructible. If adequate heat sinking is
provided, they can deliver over 1A output current. Although designed primarily as fixed voltage
regulators, these devices can be used with external components to obtain adjustable voltages and
currents. And the pin diagram is shown in figure 4.3.1

Figure 4.3.1 Pin Diagram of 7809

4.4 SILICON POWER DARLINGTON TRANSISTOR (TIP122)

DESCRIPTION

The TIP120, TIP121 and TIP122 are silicon Epitaxial-Base NPN power transistors in
monolithic Darlington configuration mounted in Jedec TO-220 plastic package. They are
intented for use in power linear and switching applications. The complementary PNP types are
TIP125, TIP126 and TIP127, respectively.
 CHAPTER 5
COMPARISON ,ADVANTAGES AND
DISADVANTAGES

5.1 COMPARISIONS BASED ON CRITERIA

Table 5.1 Comparison of Power Supply Technologies

Criteria Current Cable Contactless,Inductive

Rail/Brushes
Voltage Current DC,AC low frequency DC,AC low Frequency DC,AC high Frequency

No f Phases 1,3 1,3 1

Power Conversion No no yes

Power Range Up to MW Up to MW Up to MW

Efficiency Low-high high high

Wear and Tear Yes (rail,brushes) Yes,cable no

Maintenance Yes yes no

Reliability Medium medium high

Sensitivity Environment Dust,ice No no

Safety Aspects Not isolated /hazards Isolated isolated

EMV,EMI Effects Low Low Medium

Pollution Yes,brushes No no

Cost (Install /Maint.) Medium Medium High/low

Regarding the characteristics shown in Tab.5.1 there are some advantages and
disadvantages of contactless power transfer who are pointed as follows.

5.2 ADVANTAGES

• No wear and Tear

• High Reliability

• No sensitivity against enviornment conditions

• Fully isolated system

• No maintence requirment

5.3 DISADVANTAGES

• Complexe technology
• High power conversion

• High investment costs

HISTORY AND CURRENT STATUS

• 1988: A power electronics group led by Prof. John Boys at The University of
Auckland in New Zealand, develops an inverter using novel engineering materials
and power electronics and conclude that power transmission by means of
electrodynamic induction should be achievable. A first prototype for a contact-less
power supply is built. Auckland Uniservices, the commercial company of The
University of Auckland, patents the technology
• 1989: Daifuku, a Japanese company, engages Auckland Uniservices Ltd. to develop
technology for car assembly plants and materials handling providing challenging
technical requirements including multiplicity of vehicles
• 1990: Prof. John Boys team develops novel technology enabling multiple vehicles to
run on the same inductive power loop and provide independent control of each
vehicle. Auckland UniServices Patents the technology
• 1996: Auckland Uniservices develops an Electric Bus power system using
electrodynamic induction to charge (30-60 kW) opportunistically commencing
implementation in New Zealand. Prof John Boys Team commission 1st commercial
IPT Bus in the world at Whakarewarewa, in New Zealand
• 1998: RFID tags are powered by electrodynamic induction over a few feet.
• 1999: Dr. Herbert L. Becker powers a lamp and a hand held fan from a distance of 30
feet
• 1999: Prof. Shu Yuen (Ron) Hui and Mr. S.C. Tang of the City University of Hong
Kong file a patent on "Coreless Printed-Circuit-Board (PCB) transformers and
operating techniques", which form the basis for future planar charging surface with
"vertical flux" leaving the planar surface. The circuit uses resonant circuits for
wireless power transfer. EP(GB)0935263B
• 2000: Prof. Shu Yuen (Ron) Hui invent a planar wireless charging pad using the
"vertical flux" approach and resonant power transfer for charging portable consumer
electronic products. A patent is filed on "Apparatus and method of an inductive
battery charger,” PCT Patent PCT/AU03/00 721, 2000.
• 2000: Based on the coreless PCB transformer developed by Prof. Ron Hui, Prof. B.
Choi and his team at Kyungpook National University publish a paper on “A new
contactless battery charger for portable telecommunication/computing electronics,” in
Proc. ICCE’00 Int. Conf. Consumer Electron., 2000, pp. 58–59. The coreless PCB
transformer is used to wirelessly charge a mobile phone.
• 2001 Prof. Shu Yuen (Ron) Hui and Dr. S.C. Tang file a patent on "Planar Printed-
Circuit-Board Transformers with Effective Electromagnetic Interference (EMI)
Shielding". The EM shield consists of a thin layer of ferrite and a thin layer of copper
sheet. It enables the underneath of the future wireless charging pads to be shielded
 with a thin EM shield structure with thickness of typically 0.7mm or less. Patent:
US6,501,364.
• 2001: Prof. Ron Hui's team demonstrate that the coreless PCB transformer can
transmit power close to 100W in ‘A low-profile low-power converter with coreless
PCB isolation transformer, IEEE Transactions on Power Electronics, Volume: 16
Issue: 3 , May 2001. A team of Philips Research Center Aachen, led by Dr. Eberhard
Waffenschmidt, use it to power an 100W lighting device in their paper "Size
advantage of coreless transformers in the MHz range" in the European Power
Electronics Conference in Graz.
• 2002: Prof. Shu Yuen (Ron) Hui extends the planar wireless charging pad concept
using the vertical flux approach to incorporate free-positioning feature for multiple
loads. This is achieved by using a multilayer planar winding array structure. Patent
were granted as "Planar Inductive Battery Charger", GB2389720 and GB 2389767.
• 2004: Electrodynamic induction used by 90 percent of the US$1 billion clean room
industry for materials handling equipment in semiconductor, LCD and plasma screen
manufacture
• 2005: Prof. Shu Yuen (Ron) Hui and Dr. W.C. Ho of City University of Hong Kong
publish their work in the IEEE Transactions on a planar wireless charging platform
with free-positioning feature. The planar wireless charging pad is able to charge
several loads simultaneously on a flat surface.
• 2005: Prof Boys' team at The University of Auckland, refines 3-phase IPT Highway
and pick-up systems allowing transmission of power to moving vehicles in the lab
• 2007: A localized charging technique is reported by Dr. Xun Liu and Prof. Ron Hui
for the wireless charging pad with free-positioning feature. With the aid of the
double-layer EM shields enclosing the transmitter and receiver coils, the localized
charging selects the right transmitter coil so as to minimize flux leakage and human
exposure to radiation.
• 2008: Industrial designer Thanh Tran, at Brunel University make a wireless lamp
incorporating a high efficiency 3W LED
 • 2009: A simple analytical electrical model of electrodynamic induction power
transmission is proposed and applied to a wireless power transfer system for
implantable devices.
• 2009: Sony shows a wireless electrodynamic-induction powered TV set, 60 W over
50 cm.

REFERENCES
1. ^ Brown., W. C. (September 1984). "The History of Power Transmission by Radio Waves".
Microwave Theory and Techniques, IEEE Transactions on 32 (Volume: 32, Issue: 9 On page(s):
1230-1242+ ISSN: 0018-9480): 1230.

2. M.Ryu,et al., “Comparison and analysis of the Contactless Power Transfer System Using the
Parameters of the Contactless Transformer” in Proc. 2006. Power Electronics Specialists.

3. A. Ecklebe and A. Lindemann, “ Analysis and Design of a Contactless Energy Transmission

System with Flexible Inductor Positioning for automated Guided Vehicles ,”in Proc. 2006 IEEE
Industrial Electronics Conf.

4. URL of Sony’s Research http://www.techshout.com/wireless/2009/05/sony-unravels-technology-

for-wireless-power-transfer/

5. ^ William Beaty, Yahoo Wireless Energy Transmission Tech Group Message #787, reprinted in
WIRELESS TRANSMISSION THEORY.