Modeling, Design, and Experimental Verification of a WPT Level-3 Wireless Charger with Compact Secondary Coupler

This study introduces a wireless power transfer (WPT) Level-3 rated charger with >11 kW nominal output. The proposed system is interoperable for WPT Level-1, 2, and 3 charger applications of which power levels and airgap separations are defined in SAE J2954. The system designed for this study is capable of operating at Z1 (100-150 mm), Z2 (140-210 mm) and Z3 (170-250 mm) vehicle assembly ground clearance range classes with a very compact vehicle-side (secondary) coupler. The couplers are characterized for the maximum output power (Pout) and the coupling coefficient (k) with different airgaps. System frequency response and the sensitivity analysis are presented. Experimental results are shown for 190.5 mm and 216 mm airgap separations. These results demonstrate that the proposed system with a very compact secondary can be operated at these ground clearance classes with high efficiency at WPT level-3 charging levels.