Design and Development of a Class EF2 Inverter and Rectifier for Multi-megahertz Wireless Power Transfer Systems

This paper presents the design and implementation of a Class EF2 inverter and Class EF2 rectifier for two -W wireless power transfer (WPT) systems, one operating at 6.78 MHz and the other at 27.12 MHz. It will be shown that the Class EF2 circuits can be designed to have beneficial features for WPT applications such as reduced second-harmonic component and lower total harmonic distortion, higher power-output capability, reduction in magnetic core requirements and operation at higher frequencies in rectification compared to other circuit topologies. A model will first be presented to analyze the circuits and to derive values of its components to achieve optimum switching operation. Additional analysis regarding harmonic content, magnetic core requirements and open-circuit protection will also be performed. The design and implementation process of the two Class-EF2-based WPT systems will be discussed and compared to an equivalent Class-E-based WPT system. Experimental results will be provided to confirm validity of the analysis. A dc-dc efficiency of 75% was achieved with Class-EF2-based systems

Load-independent Class EF inverters for inductive wireless power transfer

This paper will present the modelling, analysis and design of a load-independent Class EF inverter. This inverter is able to maintain zero-voltage switching (ZVS) operation and produce a constant output current for any load value without the need for tuning or replacement of components. The load-independent feature of this inverter is beneficial when used as the primary coil driver in multi megahertz high power inductive wireless power transfer (WPT) applications where the distance between the coils and the load are variable. The work here begins with the traditional load-dependent Class EF topology for inversion and then specifies the criteria that are required to be met in order achieve load-independence. The design and development of a 240W load-independent Class EF inverter to drive the primary coil of a 6.78MHz WPT system will be discussed and experimental results will be presented to show the load-independence feature when the distance between the coils of the WPT system changes

A multi-MHz wireless power transfer system with mains power factor correction circuitry on the receiver

This paper proposes the implementation of a new system topology for multi-MHz inductive power transfer (IPT) systems, which achieves unity power factor when fed from a mains power supply without traditional active circuitry in the front-end as a mains interface. Experiments were performed using an IPT-link which consists of two 20 cm two-turn air-core printed-circuit-board (pcb) coils separated by an air-gap of 13 cm. At the transmit side, a push-pull load-independent Class EF inverter fed from a rectified 60 Hz power supply with no bulk capacitor was designed to drive the transmit coil at 13.56 MHz. This inverter, which has two choke inductors between the voltage source and the two switches, similar to that of an interleaved boost converter, is suitable to be fed directly from a rectified mains source because it tolerates large changes on the input voltage. The IPT rectifier in the experiments was built using a dual current-driven Class D-based topology which allows for higher output voltage when the induced electromotive force (emf) on the receive coil is low. The final power conversion stage on the receive side is a power factor correction (PFC) boost converter that regulates the output voltage and shapes the current waveform at the input of the system. This stage is the only part of the system with closed-loop control. The end-to-end efficiency was measured at 73.3% with 99.2% power factor, when powering a load of 150 W

Probability-based optimisation for a multi-MHz IPT system with variable coupling

This paper presents the analysis and design of a dynamic inductive power transfer (IPT) system, in which coupling is treated as a stochastic variable and is therefore modelled as a probability distribution. The purpose of this formulation is to optimise the tuning of the inverter and the rectifier to the coupling value that achieves the highest charging energy-efficiency when operating at a broad range of coupling. The analysis is supported by a case study in which two rectifier designs, using the hybrid Class E topology, are tuned at different coupling values in order to verify which version achieves the highest charging efficiency. The load in the experiments is a wirelessly powered drone without a battery hovering randomly over the charging pad, and the range of motion is set by a nylon string tether. The experiments show lower energy consumption when the rectifier is tuned to present the optimal load of the link at the coupling value with the highest probability, as opposed to the first, which was designed to present the optimal load of the link at minimum coupling

Load- and Position-Independent Moving MHz WPT System Based on GaN-Distributed Current Sources

This paper describes the modeling, analysis, and design of a complete (dc-to-dc) inductive wireless power transfer (WPT) system for industrial moving applications. The system operates at 6.78 MHz and delivers up to 150 W to a load moving along a linear path, providing a quasi-constant dc output voltage and maintaining a zero voltage switching operation, regardless of position and load, without any retuning or feedback. The inductive link consists of an array of stationary transmitting coils and a moving receiving coil whose length is optimized to achieve a constant coupling coefficient along the path. Each Tx coil is individually driven by a constant amplitude and phase sinusoidal current that is generated from a GaN-based coupled load-independent Class EF inverter. Two adjacent transmitters are activated at a given time depending on the receiver’s position; this effectively creates a virtual series connection between the two transmitting coils. The Rx coil is connected to a passive Class E rectifier that is designed to maintain a constant dc output voltage independent of its load and position. Extensive experimental results are presented to show the performance over different loading conditions and positions. A peak dc-to-dc efficiency of 80% is achieved at 100 W of dc output power and a dc output voltage variation of less than 5% is measured over a load range from 30 to 500 Ω . The work in this paper is foreseen as a design solution for a high-efficient, maintenance-free, and reliable WPT system for powering sliders and mass movers in industrial automation plants

Dynamic capabilities of multi-MHz inductive power transfer systems demonstrated with batteryless drones

This paper presents the design of a multi-MHz inductive power transfer (IPT) system showcasing lightweight and energy-efficient solutions for non-radiative wireless power transfer. A proof of concept is developed by powering a drone without a battery that can hover freely in proximity to an IPT transmitter. The most challenging aspect, addressed here for the first time, is the complete system level design to provide uninterrupted power-flow efficiently while allowing for variable power demand and highly variable coupling factor. The proposed solution includes the design of lightweight air-core coils that can achieve sufficient coupling without degrading the aerodynamics of the drone, and designing newly-developed resonant power converters at both ends of the system. At the transmittingend, a load-independent Class EF inverter, which can drive a transmitting-coil with constant current amplitude and achieves zero-voltage switching (ZVS) for the entire range of operation, was developed; and at the receiving-end, a hybrid Class E rectifier, which allows tuning for large changes in coupling and power demand, was used. For the demo, the range of motion of the drone was limited by a 7.5 cm nylon string tether, connected between the centre of the transmitting-coil and the bottom of the drone. The design of the IPT system, including all the power conversion stages and the IPT link, is explained in detail. The results on performance and specific practical considerations required for the physical implementation are provided. An average end-to-end efficiency of 60% was achieved for a coupling range of 23% to 5.8%. Relevant simulations concerning human exposure to electromagnetic fields are also included to assure that the demo is safe according to the relevant guidelines. This paper is accompanied by a video featuring the proposed IPT system

Mechanical modelling of high power lateral IGBT for LED driver applications

An assembly exercise was proposed to replace the vertical MOSFET by lateral IGBTs (LIGBT) for LED driver systems which can provide significant advantages in terms of size reduction (LIGBTs are ten times smaller than vertical MOSFETs) and lower component count. A 6 circle, 5V gate, 800 V LIGBT device with dimension of 818μm x 672μm with deposited solder balls that has a radius of around 75μm was selected in this assembly exercise. The driver system uses chip on board (COB) technique to create a compact driver system which can fit into a GU10 bulb housing. The challenging aspect of the LIGBT package in high voltage application is underfill dielectric breakdown and solder fatigue failure. In order to predict the extreme electric field values of the underfill, an electrostatic finite element analysis was undertaken on the LIGBT package structure for various underfill permittivity values. From the electro static finite element analysis, the maximum electric field in the underfill was estimated as 38 V/μm. Five commercial underfills were selected for investigating the trade-off in materials properties that mitigate underfill electrical breakdown and solder joint fatigue failure. These selected underfills have dielectric breakdown higher than the predicted value from electrostatic analysis. The thermo-mechanical finite element analysis were undertaken for solder bump reliability for all the underfill materials. The underfill which can enhance the solder reliability was chosen as prime candidate

A 600W 6.78MHz wireless charger for an electric scooter

This paper presents a 600 W electric scooter wireless charging solution operating at a frequency of 6.78 MHz. At the transmitter end, a load-independent Class EF push-pull(differential) inverter with GaN transistors was used to drive a 33 cm square-shaped copper pipe coil. A full-wave voltage-triplerClass D rectifier with silicon Schottky diodes was connected to a24 cm-by-26 cm trapezoidal receiver coil (also made of copperpipe) mounted underneath the steel frame of the scooter. In order to reduce the eddy current and magnetic losses in the steel chassis, parts of the electric scooter frame were shielded with copper tape. With the battery recharging in situ at 600 W,the IPT system achieved a DC-to-DC efficiency of 84 %

Load-independent class E/EF inverters and rectifiers for MHz-switching applications

This paper presents a unified framework for the modeling, analysis, and design of load-independent Class E and Class EF inverters and rectifiers. These circuits are able to maintain zero-voltage switching and, hence, high efficiency for a wide load range without requiring tuning or use of a feedback loop, and to simultaneously achieve a constant amplitude ac voltage or current in inversion and a constant dc output voltage or current in rectification. As switching frequencies are gradually stepping into the megahertz (MHz) region with the use of wide-bandgap (WBG) devices such as GaN and SiC, switching loss, implementing fast control loops, and current sensing become a challenge, which load-independent operation is able to address, thus allowing exploitation of the high-frequency capability of WBG devices. The traditional Class E and EF topologies are first presented, and the conditions for load-independent operation are derived mathematically; then, a thorough analytical characterization of the circuit performance is carried out in terms of voltage and current stresses and the power-output capability. From this, design contours and tables are presented to enable the rapid implementation of these converters given particular power and load requirements. Three different design examples are used to showcase the capability of these converters in typical MHz power conversion applications using the design equations and methods presented in this paper. The design examples are chosen toward enabling efficient and high-power-density MHz converters for wireless power transfer (WPT) applications and dc/dc conversion. Specifically, a 150-W 13.56-MHz Class EF inverter for WPT, a 150-W 10-MHz miniature Class E boost converter, and a lightweight wirelessly powered drone using a 20-W 13.56-MHz Class E synchronous rectifier have been designed and are presented here