Design of Lightweight High Power Density Bidirectional Magnetic Coupler

Aiming at the optimal performance of endurance bearing and heat dissipation requirements of electric vehicles, a lightweight and high power density bi-directional magnetic coupling mechanism of charge and discharge is designed. A lightweight optimization method of coupling mechanism and a lightweight design method of magnetic shield structure are proposed. While taking into account the anti-migration characteristics, weight, volume, loss and resonator loss of coupling mechanism, the size parameters of the primary secondary coil and the number of turns of coil as well as the structure and thickness of magnetic core of coupling mechanism are reasonably designed. The composite structure of nanocrystalline and aluminum plate cambium is used as a lightweight magnetic shield structure. The designed coupling mechanism can effectively reduce the weight, volume and system loss of the coupling mechanism while completing 30kW power transmission. The magnetic flux leakage of the system is also within the safe range, and the lightweight and high power density design of the coupling mechanism is realized.