A Single-Stage Reconfigurable Wireless Charger for 400-V and 800-V Electric Vehicle Battery Voltages

The electric vehicle (EV) battery packs are typically rated at 400 or 800 V. The existing inductive chargers involve multiple conversion stages and inductive couplers to charge these EVs, which increases the system’s complexity and cost. This paper proposes a new single-stage reconfigurable inductive charger to charge 400 and 800 V battery pack EVs at the same power rating with a single coupler and minimal conversion stages. This charger involves an active clamped AC-AC converter on the transmitter side and an onboard reconfigurable rectifier. Furthermore, a mode switching-based controller with an active harmonic minimization (AHM) technique is designed to attenuate the prominent second-harmonic in the sensed battery current/voltage and eradicate subharmonic oscillations. The designed coupler for 400/800 V charging is evaluated in the ANSYS-Maxwell platform. Finally, the proposed charger’s functionality has been validated through MATLAB simulations and experimental studies on a 1.2 kW silicon carbide (SiC)-based laboratory prototype.