Automotive vibration oriented design of a 100kW integrated liquid cooled wireless power transfer system

Nowadays, the significance of electrical vehicle has raised dramatically in the background of the depletion of fossil fuel resources. However, the charging technology is still in the development period, especially the wireless power transfer technology. Currently, there are merely a small number of EVs equipped with ultra-fast charging system, and none of them apply the water cooling technology, which has substantially high cooling efficiency. The ASSURED project in Europe has launched a new project to provide a charging solution for Fiat Doblo electrical version, concerning the cooling technology. In this paper, we mainly focus on the newly design of the water cooling system for this 100 kW ultra-fast wireless power transfer system, with its vibration oriented mechanism design applying machine design techniques to guarantee its fixture stability during the travel of vehicle. Besides, we also consider that this cooling system also must cool down the battery. In the beginning, we make an approximate estimation on the loss generated on the WPT and the battery. Following this estimation, we calculate the parameter needed for the cooling system. Subsequently, we use both SimulationX and Solidworks to simulate and verify the designed cooling system, using temperature as the criteria. Finally, the fixture method is chosen and verified.