New Industry Products

Receiver Antennae for EV Wireless Charging Handle up to 11kW

October 21, 2019 by Paul Shepard

PREMO has announced the WC-RX-Series (compact secondary coils) that brings to the market a highly reliable receiver coils for wireless charger applications for electric vehicles.  These antennae have been designed following the SAE J2954 guidelines and recommendations. They provide a flexible magnetic core combining Flex-Ferrite blocks with PBM (Soft-Polymer Bonding Magnetic). Current designs handle 3kW to 11kW of power, and a 22kW unit is under development.

The challenge of wireless power transfer (WPT) is to replace the conductive charging method by WPT technology while maintaining a comparable power level and efficiency. The long-term goal is to dynamically power the moving vehicles on the road, AGVs on a factory floor and/or autonomous robots and forklifts in a warehouse.

This may lead to a significant size reduced battery pack and extended driving range at the same time thus addressing the main concerns of EV, namely, the high prices of batteries and range anxiety.

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For the past 3 years, PREMO has been investing in innovative Inductive Components design applying both the 3DPower™ concept (for the magnetics involved in WPT) and the ALMA™ concept (for long-range antennae using flex-magnetic core).

A Team of Scientists from Madrid's CSIC (Superior Council of Scientific Research) led by renowned expert in Magnetism, Mr. Manuel Vazquez, Ph.D, Head of the Nanomagnetism and Magnetization Processes groups, researchers of UPM (Universidad Politécnica de Madrid), Andaltec (Instituto Andaluz del Plástico) and a team of materials scientists and technologists at Premo's Innovation Center in Malaga have developed a technology aimed at inductive WPT in the range of 90kHz.

This technology deals with the limits of conventional ferrite cores that are both fragile and brittle and cannot be manufactured reliably in the long, large and thick formats required by this application. After 3 years of research and development and more than 1 Million Euros in private and public funding, the team is announcing the first industrial solutions that overcome the limits of the technology used to this date.

The main improvement in performance of Premo's WC-Rx-Series (secondary coils) is the magnetic core technology that provides a super high efficiency (above 95%) power transfer thanks to a carefully crafted combination and optimization of the coil (Litz wire) with a flexible-core configuration that avoids air gaps and reduces heating areas. The result is a compact secondary coil with a high Q-factor (very low losses) and high reliability.

Samples of the WC-RX @ 7-11kW will be available on Premo's web page by the end of Q4-2019.

Samples of the WC-RX @ 22kW) will be available by Q1 (2020).

WC-TX-Series (Emitters) will be available in Q1 (2020).