Modern Solution of Inductive Charging System for 800 V Batteries of Electric Vehicles

The increased popularity of battery electricvehicles (BEVs) in last years shifted focus of the research and development activities towards future technologies for the charging infrastructure. The inductive charging of BEVs' batteries is an emerging charging method that is convenient, robust, safe, and efficient. In this paper two subjects are covered: the inductive charging system (ICS) 11 kVA and the auxiliary power supply (APS) of that system. The paper first provides a brief outlook of trends regarding BEVs, market for wireless inductive charging, and system needs. Then it addresses the ICS 11 kVA. The system efficiency measurement results are provided as well as common challenges. The second part of this paper is about architecture, design and operation, experimental results, and lessons learned during development of the APS of the ground assembly for the ICS. The chosen topology for that was an active-clamped flyback (ACF) dc-dc converter. Moreover, short notes on hardware engineering aspects within automotive environment (i.e. Automotive SPICE®) and relevant standards, needed for the hardware developers, are provided. In addition, a solution is presented on how to obtain the missing data, in IEC 60664–4 standard, which are needed for calculation of the safety distances.