Manufacturing influences on transmission efficiency and thermal integration of resonant circuit modules of inductive power transmission systems for electric vehicles

Electromobility is the backbone of modern emission-neutral transportation systems. Wireless energy transfer via induction is the associated complementary technology that significantly improves the user-friendliness of energy supply in various use cases such as static or dynamic wireless power transfer (WPT). The functionality of WPT for electric vehicles is extensively demonstrated, but no automatable manufacturing processes exist to produce them in large scale. Therefore, this paper describes the manufacturing process chain of coil modules of inductive power transfer (IPT) systems and presents quality criteria for these coil systems. Using structured design of experiment (DOE), the manufacturing influences on the quality of the coil modules are presented and quantified. In addition, embedding concepts of the ground assembly (GA) capacitor configuration are qualitatively evaluated.