Integrated Coil Design for EV Wireless Charging Systems Using LCC Compensation Topology

The double-sided LCC topology provides a highly efficient compensation method for electric vehicle (EV) wireless charging systems. However, the two compensated coils occupy a large volume. In order to address the volume increase as well as to be compatible with unipolar coil structures, which are widely applied in EV wireless charging systems, an integration method is introduced in this paper. Aspect ratios of the compensated coils are studied to minimize the respective coupling effect. With the proposed integration method, the extra coupling coefficients are either eliminated or decreased to a negligible level. A wireless charging system with the proposed integration method is built and the experimental results show that the system resonates at 85 kHz and delivers 3.09 kW with a dc–dc efficiency of 95.49% at an air gap of 150 mm. Furthermore, a comparison with the integration method into bipolar coil structures is presented and the results demonstrate that the system with the proposed integration method is more immune to front-to-rear and vertical misalignments.