High Power Density Z-Source Resonant Wireless Charger With Line Frequency Sinusoidal Charging

Wireless charger for electric vehicles (EVs) is an offline application and it needs power factor correction (PFC) function, which usually consists of a front-end boost PFC and a cascaded dc-dc converter. Z-source resonant converter (ZSRC), a single-stage solution with low cost and high efficiency, was proposed for EV wireless charger lately. The Z-source capacitors in the ZSRC are designed to absorb the double-line frequency ripple in this single-phase application. Sinusoidal charging, which allows the double-line frequency ripple propagate to the output, is another solution aiming at reducing the bulky capacitors. Recently, a comparison of low-frequency (120 Hz) sinusoidal charging and dc charging shows a negligible impact on Li-ion batteries' performance. Therefore, the ZSRC's capacitor, the biggest component, can be reduced dramatically from millifarad to several microfarads with a sinusoidal charging technique, which features the ZSRC high power density. Also, it keeps the Z-source's benefit of boost ability and being immune to shoot-through problems. In this paper, the sinusoidal charging behavior for the ZSRC is modeled, and a control scheme that has both PFC function and load regulation for sinusoidal charging is proposed. This control scheme can pass IEC61000-3-2 Class A criterion. Experimental results based on a 1-kW prototype with 20 cm air gap between the primary and secondary side are presented to illustrate the proposed control scheme.