A dual full-bridge series-series resonant IPT system for ultra-wide-range electric vehicle battery applications

The design of inductive charging systems presents a significant challenge for various electric vehicle models, each equipped with diverse battery packs ranging from 200 to 800 V. Typically, DC–DC converters, along with diode bridge rectifiers or controlled rectifiers, are employed to accommodate this wide battery voltage range. However, this conventional approach increases vehicle weight and introduces greater control intricacies. In response, this article proposes a wide-gain converter with two sets of coupled coils to charge batteries of different voltage ranges without compromising system efficiency. The proposed system operates in four modes: voltage doubler mode, current doubler mode, full-bridge mode, and half-bridge mode, which has high voltage gain, high current gain, medium voltage gain, and low voltage gain operations. The simulations have been performed using MATLAB-Simulink software to validate the efficacy of the dual full-bridge converter across various battery voltages (800 V, 400 V, and 200 V) and power levels. Furthermore, a laboratory prototype has been built with SiC devices to further validate the proposed converter.