Silicon Carbide Based Power Efficienct, Compact, and Extended Range Wireless Power Transfer System for Robotic Applications

Wireless power transfer (WPT) is an emerging technology with applications spanning various power levels, ranging from low power level for mobile devices charging to high power rating for electric vehicle (EV) charging. While numerous studies have been conducted in these domains, there are relatively less research efforts and market products focusing on the medium power range applications such as automated guided vehicles (AGVs). In this work, an inductive coupling wireless power transfer (ICWPT) system is introduced to address the coupled electrical-thermal challenges for further enhancing power density, power efficiency, and charging distance with misalignment tolerance concurrently, which are achieved by leveraging 3D integration and packaging technologies, customize-designed driver-integrated wide bandgap power semiconductors silicon carbide (SiC) MOSFETs power modules, and a self-derived dynamic feedback algorithm (DFA) control. Detailed overall system architecture, circuit operation, and control methodology will be discussed. A 1 kW ICWPT experimental prototype is built and verified that the power density of power receiving unit, the maximum grid-to-rectifier power efficiency, and charging distance are respectively further improved to 0.6 W/cm
³
, ≥ 90%, and 10 cm. A demonstration of wireless charging an AGV is illustrated to prove the feasibility and effectiveness of proposed ideas.