A 1-kW Contactless Energy Transfer System Based on a Rotary Transformer for Sealing Rollers

This paper introduces an innovative contactless energy transfer system for power supplying rotatable parts of automatic machineries as a robust alternative to sliding contacts. The design procedure of the key system devices, such as the dc/ac converter and the rotary transformer with its windings, is discussed. Different configurations in terms of switching network, number of turns, wire, and compensation are discussed with respect to their impact on the system efficiency and power factor. A thermal model to account for the core temperature is also introduced. Two setups, operating at 50 kHz and able to transfer up to 1.3 kW in a contactless fashion, are realized and tested to supply sealing roller resistors of automatic machineries. The system prototypes are then experimentally tested to validate the analytical models and the finite element simulations of the entire wireless power transfer link. Trade-offs emerge from the setups, in particular concerning efficiency, power factor, and electro-magnetic compatibility. As a consequence, we discuss the choice of the optimal configuration depending on the final application.