Analysis, Design, and Validation of a Decoupled Double-Receiver Wireless Power Transfer System with Constant Voltage Outputs for Industrial Power Supplies

Unwanted cross-couplings greatly hinder the development of double-receiver wireless power transfer (WPT) systems. Whenever the air gap changes or misalignment occurs, cross couplings disrupt the system stability. This article investigates a magnetic coupler for a double-receiver WPT system, which dramatically suppresses the unwanted cross-couplings. Two types of undesirable couplings are significantly reduced by using orthometric DD coils and Q-shaped coils. First, the unwanted couplings between receivers can be eliminated, validated by the measured coupling coefficient kAB = 0.003. Therefore, two receivers can work independently. Second, the unwanted couplings among the source coil and receivers can be eliminated (k1A = 0.003 and k1B = 0.003), resulting in load-independent constant voltage output. Compensation networks can also be designed straightforwardly. In addition, the inverter can achieve zero phase angle, alleviating volt-ampere rating and increasing efficiency. Thanks to the presented structure, this coupler design process is efficient because the decoupling is from the shape rather than turns. Also, it can be easily generalizable to other output voltage or power levels since turns can be changed to meet different charging demands. Validated by a laboratory prototype, experimental results successfully show remarkable agreement with the theoretical analysis, ensuring 72 V load-independent constant output voltages. It also realizes a 90.16% maximum measured overall dc-dc power transfer efficiency with 12 cm air gaps when delivering 518.4 W to two 20 Ω loads.