A 1-kW Wireless Power Transfer Link for Welding Rollers

This paper proposes an innovative approach to inductive wireless power transfer links based on a contactless energy transfer device. The key parts of the device, that are a rotary transformer and its windings, are presented. Since many con¯gurations are possible, in terms of number of turns, wire, and compensation, di®erent con¯gurations are also discussed. Two setups able to transfer up to 1.3kW in a contactless fashion are also prototyped and tested as replacements for slip rings used to supply welding roller resistors of automatic machineries. Experimental measures carried out on the test bench are used to validate the analytical model and the ¯nite element simulations of the wireless power transfer link. Trade-o®s emerge from the setups, in particular concerning e±ciency and electro-magnetic compatibility. As a consequence, the choice of the optimal con¯guration depends on the ¯nal application.