Page 59 - Research Report 2021 - Institut für Leichtbau und Kunststofftechnik

i3U

Integration von induktiven Ladesystemen in Unterbodenstrukturen

In the i3U project, an ultra-thin, highly integrated inductive charging module Period
for automotive wireless charging systems was developed which increases in- 01.02.2017 – 31.10.2020
stallation space utilization in the vehicle underbody without simultaneously
reducing ground clearance. For this purpose, an interdisciplinary develop- Project management
ment process for functionally integrated mechanical-electrical lightweight sys- Prof. Dr.-Ing. Niels Modler
tems was designed and implemented. In this context, electrical, mechanical
and process characterization of high-frequency litz wire, ferromagnetic sheet Contact
and metal wire mesh were carried out for the first time. Complementing the Martin Helwig
development, a multiphysical simulation model was set up from component Dr.-Ing. Anja Winkler
to system level to calculate the electromagnetic-thermal behavior. This was
successfully validated on the hardware-in-the-loop test bench with the hard- Project partners
ware demonstrator, which was manufactured in a 3-stage process using RTM Mercedes-Benz AG
and VARI. With an assembly height of 15 mm and a total weight of 8 kg, the
charging system achieves a transmission efficiency (according to SAE J2954) Funding
of up to 92 % at 7.2 kW nominal power and active air cooling.

Mercedes-Benz AG

Inductive 7.2 kW charging module with 92% efficiency and thickness of 15 mm.

© Mercedes-Benz AG and ILK/TUD
CAD sectional view of the charging module and representation of the individual compo-
nents.

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