Dec 16, 2021
Convenient charging without cables? – Easy-going!
AVK Award 2021 in the category Research and Science: f.l.t.r. Prof. Dr. Jens Ridzevski (AVK), Prof. Dr. Niels Modler (ILK), Steve Zimmer (Mercedes-Benz AG), Reinhard Lux (AVK).
The AVK Innovation Award 2021 for a highly integrated and ultra-thin vehicle module for wireless charging
Numerous technical challenges have to be solved before structurally integrated wireless charging systems for automotive applications are ready for the market. For example, the increased space requirements of currently commercially available charging modules prevent an efficient integration into the vehicle. Researchers from the Institute for Lightweight Engineering and Polymer Technology (ILK) at TU Dresden and Mercedes-Benz AG have tackled this problem. In close collaboration, an ultra-thin in-vehicle charging module was developed. With the design of this receiver module, a decisive milestone was reached in terms of the design, manufacture and especially the application of function-integrated lightweight structures in automotive, as well as cross-industry applications. For this achievement, the work was awarded one of the prestigious AVK Innovation Awards 2021.
The AVK - Industrievereinigung Verstärkte Kunststoffe e.V. and AVK-TV GmbH awards the prestigious innovation prizes annually to companies, research institutes and their partners. The interdisciplinary development of the highly integrated inductive charging module for electric vehicles, which covered both the mechanical and electrical aspects, was awarded a prize in the Research and Science category. The award ceremony honoring Prof. Dr. Niels Modler for the ILK and Steve Zimmer for Mercedes-Benz AG took place on November 23, 2021 in Frankfurt.
Highly integrated and ultra-thin: In the joint research work, an ultra-thin inductive charging module for electric vehicles was implemented for the first time. With an installation height of only 15 mm and a weight of approx. 8 kg, the innovative charging module significantly increases the utilization of installation space without reducing the ground clearance of the vehicle. Compared to the reference system, a 62% reduction in vertical body height and a 50% weight saving have been achieved. At the same time, the charging system achieves a transfer efficiency of up to 92% at 7.2 kW nominal power with active air cooling.
(a) 7.2 kW inductive charging module with 92% transfer efficiency and 15 mm in thickness. (b) CAD sectional view of the charging module and illustration of the individual components.
Two-box design with innovative magnetic circuit components: The space-saving charging module is made possible by the innovative two-box design, which separates the components exposed to the magnetic field from the power electronics. While the power electronics can then be freely positioned in the vehicle, the magnetic circuit components can be functionally integrated into a plastic component. The latter could be realized through the first-time adoption of innovative materials such as nanocrystalline ferromagnetic foils and metallic shielding meshes. In the future, the developed design enables free positioning of the inductive charging module in the underbody of electric vehicles.
Project management for the ILK:
Prof. Dr.-Ing. Niels Modler (Chair of Function-integrative Lightweight Engineering)
ILK-Contact:
Dipl.-Ing. Martin Helwig, Tel.: +49 (0) 351 463-38663,
Dr.-Ing. Anja Winkler (Head of Function integration),
Tel.: +49 (0)351 463-38074,