Design of 3D Wireless Power Transfer System Based on 3D Printed Electronics

Hou, T.; Xu, J.; Elkhuizen, W.S.; Wang, C.C.; Jiang, Jiehui; Geraedts, Jo M.P.; Song, Y.

doi:10.1109/ACCESS.2019.2928948

Design of 3D Wireless Power Transfer System Based on 3D Printed Electronics

Journal article (2019)

Authors

T. Hou Mechatronic Design - , School of Mechatronic Engineering and Automation

J. Xu Mechatronic Design -

W.S. Elkhuizen Mechatronic Design -

C.C. Wang Chinese University of Hong Kong

Jiehui Jiang Shanghai Institute for Advanced Communication and Data Science, Shanghai University

Jo M.P. Geraedts Mechatronic Design -

Y. Song Mechatronic Design -

Research Group

Mechatronic Design () (TU Delft)

DOI: https://doi.org/10.1109/ACCESS.2019.2928948

Design IPT 3D printed electronics WPT OA-Fund TU Delft 3D coil

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Published Date

2019

Language

English

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Faculty

Industrial Design Engineering

Department

Sustainable Design Engineering

Research Group

Mechatronic Design

Abstract

2D coil design limits the use of wireless power transfer (WPT) in many products with freeform outer shapes. In this paper, enabled by 3D printed electronics, we propose a systematic approach to design and fabricate 3D coils for WPT. Based on the circular spiral and rectangular spiral patterns, 3D receiver and transmitter coils can be generated on an arbitrarily selected region of a product and its offset, respectively. Mathematical models are proposed to estimate the self-inductance and the mutual-inductance of the 3D arbitrarily shaped coils for 3D WPT. This leads to a new design approach of a 3D WPT system. Several sets of 3D printed WPT systems were designed, simulated, and prototyped to demonstrate the effectiveness of the proposed design approach as well as the mathematical models. The calculation speed of the proposed mathematical models is 30 times faster than the simulation, and compared with the measurement results, the calculation results have mean absolute errors of 2.63% and 4.45% regarding the self- and the mutual-inductance, where the simulation results have mean absolute errors of 1.20% and 2.38%, respectively. Measurements also indicate that with a 5V input, the prototypes are able to deliver 1-watt power at an efficiency ranging between 20.9% and 25.3%. It was concluded that the proposed approach is feasible and promising for designing and manufacturing WPT using 3D printed electronics.

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