A 50-kW Three-Phase Wireless Power Transfer System Using Bipolar Windings and Series Resonant Networks for Rotating Magnetic Fields

The mass and volume of wireless power transfer (WPT) systems for charging electric vehicles are directly related to the rated power of the system. The difficulties of high-power wireless charging are exacerbated by the need to meet the same practical constraints associated with vehicle integration as lower power systems. Therefore, more advanced techniques are necessary to improve power density and specific power of wireless charging systems for high-power applications. This article presents theory and analysis of three-phase inductive WPT systems with bipolar phase windings. Magnetic coupler topologies and the theoretical and practical aspects of series three-phase resonant compensation networks are discussed. The systems under consideration are designed to utilize rotating magnetic fields to achieve a power transfer characteristic that is temporally smoother than single-phase systems. Other benefits associated with rotating magnetic field based WPT, including reduced ferrite mass, filter component requirements, and electromagnetic field emissions, are discussed. Experimental results of a prototype system are presented in both aligned and misaligned configurations. The system is demonstrated transferring 50 kW with 95% dc-to-dc efficiency over a 150-mm airgap in the aligned case. On a per-pad basis, the magnetic couplers achieve a power density of 195 kW/m$^2$ and a specific power of 3.65 kW/kg. This article is accompanied by a video of the rotating magnetic field produced by a simulated three-phase WPT system.