A Constant Current Wireless Power Transfer Scheme with Asymmetric Loosely Coupled Transformer for Electric Forklift

Due to the numerous advantages such as being convenient, safe, and contactless, wireless power transfer (WPT) is becoming the mainstream charging method for electric vehicles. This paper presents a constant current WPT system with asymmetric loosely coupled transformer for electric forklifts using lead-acid batteries. First, based on the Neumann formula, this paper analyzes the mutual inductance of the coaxial rectangular coil, and designs an asymmetric loosely coupled transformer based on the practical application requirements, which makes the secondary side light and miniaturized. Second, the WPT system is analyzed in terms of the requirements of constant current charging, and the dual-LCL compensation is proposed according to the output current and power requirements. The transfer characteristics and anti-interference capability of the topology are analyzed. The constant current output feature of the system under the condition of variable load is demonstrated. After that, a dual-active bridge secondary-side independent control strategy is proposed, the phase shift angle is adjusted to ensure constant charging current and high efficiency of the system. Finally, a wireless charging experimental platform is established in accordance with the proposed asymmetric loosely coupled transformer and WPT system. The system can achieve 45 A constant current output and 3 kW output power with 91.2% transmission efficiency.