Thermal Analysis of a 50 kW Three-Phase Wireless Charging System

In this paper, the thermal analysis of a 50 kW three-phase wireless charging system (WCS) is presented. Addressing the thermal challenge is essential for designing a compact charging pad for 50 kW and higher-power WCS pads. Low thermal conductivity of the Litz wire and ferrite, and uneven distribution of the coil, and core loss cause the high temperature in the charging pads. In this paper, the loss distribution of a 50 kW three-phase WCS is investigated, and the temperature distribution is simulated using finite element analysis (FEA) considering the magnetic and non-magnetic materials of a charging pad. The thermal characteristics of an extremely high-power density 50 kW WCS prototype are tested experimentally for 10 minutes of operation. The simulation and experimental results show that the coil temperature increases to 65°C, the core temperature varies between 50°C to 150°C, and the packaging temperature increases to 65°C after 10 minutes of operation at rated 50 kW output power.