on
Bachelor of Technology
In
Submitted By
CERTIFICATE
This seminar has been compiled & completed under the expert guidance of
ECE department personnel. I hereby heartily acknowledge their unstinted
help & valuable assistance.
DIWAKAR BANSAL
SANTOSH KR. VAISH
ANKIT SINGH
4th Year (E.C)
Deptt. of Electronics and Communication Engg.
GLBITM, Greater Noida
TABLE OF CONTENTS
ABSTRACT v
1. INTRODUCTION
1.1 Objectives...............................................................................................................1
1.2 Specifications..........................................................................................................2
1.3 Block Diagram........................................................................................................2
1.4 Subprojects.............................................................................................................3
1.4.1 DC Source....................................................................................................3
1.4.2 Full-Bridge Inverter.....................................................................................3
1.4.3 Gate Drivers.................................................................................................3
1.4.4 PIC...............................................................................................................4
1.4.5 DAC/VCO....................................................................................................4
1.4.6 Current Sensing............................................................................................4
1.4.7 Coils and Air Gap........................................................................................4
1.4.8 Transformer..................................................................................................4
1.4.9 Rectifier/Filter..............................................................................................5
1.4.10 Buck Converter..........................................................................................5
2. DESIGN PROCEDURE...............................................................................................6
2.1 DC Source...............................................................................................................6
2.2 Full-Bridge Inverter/Gate Drivers..........................................................................6
2.3 PIC, DAC, and VCO..............................................................................................7
2.4 Current Sensing......................................................................................................7
2.5 Coils and Air Gap...................................................................................................7
2.6 Transformer............................................................................................................8
2.7 Rectifier and Filter..................................................................................................9
2.8 Buck Converter.......................................................................................................9
3. DESIGN DETAILS....................................................................................................10
3.1 DC Source.............................................................................................................10
3.2 Full-Bridge Inverter/Gate Drivers........................................................................11
3.3 PIC, DAC, and VCO............................................................................................12
3.4 Current Sensing....................................................................................................13
3.5 Coils and Air Gap.................................................................................................13
3.6 Transformer..........................................................................................................14
3.7 Rectifier and Filter................................................................................................14
3.8 Buck Converter.....................................................................................................14
4. COMPONENT USED................................................................................................15
4.1 Parts......................................................................................................................15
5. CONCLUSIONS........................................................................................................16
5.1 Accomplishments.................................................................................................16
5.2 Uncertainties.........................................................................................................16
REFERENCES..................................................................................................................17
1
1. INTRODUCTION
In the age of wireless communication and portable music players the
demand for powering those devices wirelessly is ever prevalent. The
advantages of portability and wireless communication are greatly hindered
by the fact that the devices themselves must be plugged into the walls to
charge. The next generation in portable devices is a device that receives
power wirelessly. The first step in wireless power is providing power to a
computer charging pad wirelessly. The market for this device would be
businesses with large conference rooms. The device would allow users to
plug their phones and computers into the conference room table without
large power bricks and cords running everywhere. The pads can
conveniently be placed under the table and inside the ceiling so there are no
visible wires that could ruin the aesthetic feel of the room. The ease of
installation and convenience of this device would make the marketability of
this product quite large and if finished could be seen in thousands of
conference rooms. If the efficiency of coupling could be increased slightly
further, wireless power transmission could become a standard means for
charging a mobile device.
1.1 Objectives
1.2 Specifications
P IC
Feedback
C u rre n t S e n so r D A /CV C O G a t e D r iv e r C
s
o n tr o l
M ic r o c o n to lle r
DC F u-Bll r id g e
W a ll V o lta g e T o p C o il A ir G a p B o t t o m C o il
S o u rce In v e r t e r
D C/D C
B u c k C o n v e r te r s
C e ll P h o n e R e c t ifie r a n d F ilte r T r a n s f o r m e r
L a p to p
1.4.1 DC Source
The DC source takes in the input from the wall voltage which is a 60 Hz
sinusoid. Using diodes, the voltage is rectified and passed through a PI
filter. The original design specified a 1 % voltage ripple, but this ripple
requirement was excessive and difficult to meet at such a low frequency.
The final design chosen had a voltage ripple of less than 5 % and was more
than suitable.
The full bridge inverter is a circuit that uses four switches, a DC source, and
a load. The four switches are setup in an H-bridge with the middle being the
load. In this case the load is the top coil. Two of the switches are connected
from the high side DC source to opposite sides of the coil. The remaining
two switches are connected from the low side of the DC source to opposite
sides of the coil. High side switches have opposite duty cycles and the low
side switches are connected such that the DC source is applied across the
load. The result is a square wave being applied across the coil. The switches
are MOSFETs that have the capability to carry the max current and can
block the full DC voltage.
Gate drivers are used to turn on and off the switches. The gate drivers take
in a timing signal and output a voltage high enough and with enough current
to drive MOSFETs on and off at the same frequency of the timing signal.
4
The gate drivers are controlled by a PIC microcontroller. There is feed back
into the PIC about how much power is being drawn. The PIC attempts to
increase the frequency until the power out of the DC source is at a
maximum. This should correspond to the resonant frequency because the
increase in input power means there is an increase in output power. The PIC
outputs 10 digital logic pins as either high or low. The pins are then
converted to a voltage by the Digital to Analog Converter (DAC).
The current sensing circuit is used to tell the PIC how much current is being
pulled from the DC source. It uses a precision .15 Ω resistor on the output of
the DC source and that voltage is feed into an op-amp circuit that produces a
voltage proportional to the current. This voltage is designed to be within the
range of inputs for the PIC.
The coils are each made out of 100 turns of 20 AWG magnet wire. They are
separated by about 2 m and have a diameter of about 1 m. The power
transfer between them is done through resonant magnetic coupling.
1.4.8 Transformer
2. DESIGN PROCEDURES
The overall concept for mutually inductive coils is an idea from an MIT
experiment used to transmit power to power a light bulb. The size of the
inductors was increased and the number of turns increased due to ideal
equations in hopes of lowering resonant frequency and increasing
transmission efficiency. PSPICE simulation was done wherever possible to
verify design before actual testing.
2.1 DC source
The DC source was designed with a rectifier and filter circuit. A full bridge
rectifier was chosen because they have less ripple than a half bridge rectifier
because the frequency is twice as fast. This means the filter has to supply
the voltage for only half as long so it has less time to decay. Figure 2 shows
the difference in the two rectifiers.
The capacitors were chosen with relatively high values and the design
choice was verified in PSPICE with a simulation
The full bridge circuit is a generic circuit. The switches were chosen based
on max frequency, current carrying capabilities, and voltage blocking. The
speed is important because our switching frequency is several MHz at high
voltage and a reasonable amount of current. The gate drivers were chosen
because they have the appropriate frequency requirements and are designed
to drive MOSFETs, also they have an inverting and non-inverting signals.
This means that it can drive all of the MOSFETs.
7
The PIC was chosen because it was readily available, has an analog input
for feedback, and it can operate at a speed that is fast enough to control the
frequency. The PIC outputs a 10 bit logical signal that is converted to a
voltage by a DAC. The DAC was chosen similar to the PIC in that it was
readily available, has the ability to convert the digital pins to the analog
voltage range needed. C-code already generated for the PIC did not have to
be changed with the operation of this new DAC. The output voltage of the
DAC is an input to the VCO. The VCO was chosen because of its frequency
range.
The Transistor part numbers were changed based on what was available in
the parts shop. The fact that the circuit had to handle a common mode
voltage of around 170 V made the circuit more complicated than normal
current sense circuits. The zener diode and the p-type MOSFETs in the
design allow the high side voltage to be as high as 500 V, while only
making the voltage supply to the op-amp around 62 V and taking care of
any common mode voltage problems by referencing to a voltage other than
ground.
The coils were designed using a series of ideal equations. If the coils are
treated as windings around a transformer the reluctance can be calculated
using equation.
l
ℜ=
µo µ r A
Using the dimensions given and the relative permeability of air the
A
reluctance is 2.026 x106 . The reluctance can be used to find the mutual
Nm
inductance using equation.
4π N1 N 2 4π N1 N 2 µo µ r A
M= =
ℜ l
8
1 l
f = =
2π MC 2π 4π N1 N 2 µo µ r AC
2.6 Transformer
The transformer was designed based on the turn ratio needed to scale down
the voltage and current requirements to prevent magnetic flux saturation of
the core. The saturation magnetic flux is given by.
imax µ N
Bsat =
l
The core losses were attempted to be minimized using. The number of turns
was kept to a minimum to prevent losses from series resistance in the
windings.
The rectifier was chosen using a single diode to prevent loss because there
is only current flowing through one diode and the frequency is fast enough
that the full-wave is not need. The diode chosen had its frequency verified
by looking at [12]. The capacitor was picked such that its resonant
frequency is above 6 MHz because it will not act like a capacitor above this
frequency. The inductance from the connections dominates the impedance,
and a smaller capacitor was chosen than in the top filter because the self
resonant frequency is higher. Ceramic capacitors tend to have a lower
capacitance than electrolytic capacitors, but in this case the frequency is
high enough that a lower capacitance is acceptable.
The component was selected because it can handle the power necessary for
the cell phone, outputs 5 V, and meets the power requirements for the cell
phone.
A series inductor and a capacitor to ground will filter the signal output by
the buck converter making it a cleaner signal.
10
3. DESIGN DETAILS
3.1 DC Source
The 1N1188 diodes were chosen because they can carry more than 1 A and
can block up to 400 VDC. They were also readily available in the parts
shop. The voltage ripple from this circuit is hard to calculate on paper due
to the fact that it is a third order filter. The inductor was chosen at a standard
part value and verified in PSPICE that it can regulate the current properly.
A PSPICE simulation was run with Dbreak diodes in place of the 1N1188,
because there is no PSPICE model available for the 1N1188. The diodes
should not noticeably affect the output voltage.
The output signal is connected by switches operating at the speed that the
full-bridge inverter is expected to operate at. The purpose of the switches is
not to test the full-bridge inverter circuit, but make sure that the output
voltage is properly regulated.
This circuit diagram in Figure 4 is what was used to simulate. The switches
were used to make the circuit more like the real circuit that would be
running in the demo.
As Figure 5 shows, after about 40 ms the voltage is very steady. It has a
ripple of less than 1 V. When the circuit in Figure 3 was built, the regulation
was not as steady as shown in the simulation of Figure 5 so the capacitance
values were changed to 1000 µF.
11
This inverter takes in the voltage from the DC source and through using the
PIC and gate drivers, outputs signal in the form of a square wave with a
frequency that is controlled by the PIC and is adjusted based on induced
current in the coil. The gate drivers are ICs that take in the signal from the
VCO and output the right amount of voltage to turn on and off the power
MOSFETs in the full-bridge inverter.
12
The DAC requirements were that it had 10 bits, parallel inputs, and
transparent output. Finding a part that meet these restrictions was difficult.
The PIC will control the frequency of the signal that is driving the coil. It
will also adjust the frequency based on the current that is sensed through the
top coil to get the most power transfer through the coils
M CLR’/VPP RB7/PGD ` D7
From Current D6
RA0/AN0 RB6/PGC
Sensing Circuit
RA1/AN1 RB5 D5
RA2/AN2/Vref-/Cvref RB4 D4
RA3/AN3/VREF+ RB3/PGM D3
RA4/T0CK1/C1OUT RB2 D2
RA5/AN5/SS;/C2OUT RB1 D1
RE0/RD;/AN 5 RB0/INT
D0
RE5/W R’/AN6 VDD
RE2/CS’/AN7 VSS
From 5V Source VDD
PIC16F877A RD7/PSP7
High
From 5V Source
Low VSS RD6/PSP6
OSC1/CLKI RD5/PSD5
OSC2/CLKO RD4/PSD4
D8 RC0/T1OSO/T1CKI RC7/RX/DT
RCI/T1OSI/CCP2 RC6/TX/CK
D9
RC2/CCP1 RC5/SDO
RC3/SCK/SCL RC4/SDI/SDA
RD0/PSP0 RD3/PSP3
RD1/PSP1 RD2/PSP2
A very low resistance resistor will be put in series with the coil. The voltage
is then measured across it to determine the current through the coil based on
the voltage drop and resistance. The extra parts in this circuit are to protect
the op-amp. The op-amp was not rated for 150-170 V common mode
voltage, but it was found on the datasheet that this circuit would work [8].
3.5 Coils
These frequencies were far from the expected frequency. This could be due
to a multitude of factors including skin effect of the 20 AWG wire,
imperfections in the windings, incorrect permeability numbers, incorrect
estimates of capacitance, and fringing among others. The high frequency
made the designs a bit more restricted.
3.6 Transformer
The transformer was not made because we were never able to get a voltage
on the bottom coil so it was hard to figure out a turn ratio and what the
saturation current would be.
A diode that will take the signal induced in the bottom coil and cut off the
negative side of the AC, helping to create a DC signal.
Filter: A series 1mH inductor and a capacitor to ground that will filter the
signal output by the rectifier making it a smoother signal.
4. COMPONENT USED
The final product is designed to operate off a wall outlet. The only other
considerations for cost are placing the bottom coil under the table top. The
final design would also need some voltage supplies (5 and ±12).
4.1 Parts
TABLE 2: ESTIMATED COMPONENT USED
Part Block Quantity
Current Sensing Resistor Current Sensor 1
62 V Zener Diode Current Sensor 1
Operational Amplifier Current Sensor 1
2.7kΩ, 100Ω, Current Sensor 1
and 2M Ω Resistors 1/4W
Current Senor MOSFETS Current Sensor 2
Diodes DC Supply 4
1mH Inductor DC Supply 2
Capacitor 1000uF DC supply 2
40PIN PIC PIC 1
20 MHz Oscillator PIC 1
Voltage Controlled Oscillator DAC/VCO 1
DAC DAC/VCO 1
Gate Driver Gate drivers 2
Full-Bridge Inverter MOSFETs Full-Bridge Inverter 4
700m Magnet Wire (20AWG) Top and bottom coils 1
Scaffolding Wood Top and bottom coils 1
Transformer Transformer 1
Diode Bottom Filter 1
Capacitor 1uF Bottom Filter 1
Resistor 2.7K Buck Converter 1
Buck Converter Buck Converter 1
Capacitors 100uF, .01uF, and Buck Converter 1
470Uf
100uH Inductor Buck Converter 1
16
5. CONCLUSION
5.1 Accomplishments
5.2 Uncertainties
• MOSFETs were not able to operate fast enough to drive the coils at
resonance.
• Isolation problems for the inverter.
17
REFERENCES
1. http://en.wikipedia.org/wiki/Wireless_energy_transfer.
2. http://www.electricalternative.com/wireless.htm.
3. SIXTH INTERNATIONAL SYMPOSIUM NIKOLA TESLA
October 18 – 20, 2006, Belgrade, SASA, Serbia
4. http://novaspivack.typepad.com/nova_spivacks_weblog/2003/0
8/i_want_wireless.html.
5. http://ecoupled.com/applicationsMain.html
6. http://www.wired.com/gadgetlab/2009/01/video-wireless/
7. http://www.instructables.com/id/Wireless-Power-Transmission-
Over-Short-Distances-U/
8. http://web.mit.edu/newsoffice/2007/techtalk51-30.pdf
9. http://www.electronicsinfoline.com/New/Lights_and_Optics/wire
less-power-transmission-over-short-distances-using-inductive-
power-transfer.html