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<p>This paper presents the design and experimental validation of a 22&#xa0;kW LCC–CCL wireless charging system (WCS) developed for 800&#xa0;V electric-vehicle (EV) platforms. The proposed system integrates a three-phase power-factor-corrector (PFC), a dual-interleaved buck converter serving as the battery-management (BM) stage, and an inductive-power-transfer (IPT) converter within a unified control framework, enabling seamless operation across constant-current (CC), constant-power (CP), and constant-voltage (CV) charging modes. To ensure high-efficiency power transfer under wide load and misalignment conditions, an LCC–CCL compensation network is analytically designed to maintain zero-voltage switching (ZVS) and a constant-current characteristic at a fixed operating frequency of 85&#xa0;kHz. A complete system model, including magnetic-pad design, impedance matching, and real-time coordination among the PFC, buck, and IPT converters, is established. A 22&#xa0;kW prototype, implemented using 1200&#xa0;V-class SiC devices, achieves 93.87% peak efficiency, a power factor above 0.985, and a total harmonic distortion (THD) below 4% across a 500–860&#xa0;V battery-voltage range, even under Z1-class, 75&#xa0;mm × 100&#xa0;mm misalignment. Compared with existing 400&#xa0;V or single-stage WCS architectures, the proposed platform demonstrates superior scalability and dynamic stability for next-generation WPT4 level high-voltage EV applications. Experimental results verify that the integrated PFC-buck-IPT control strategy provides a practical and efficient solution for future high-power wireless-charging systems.</p>

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22 kW LCC-CCL wireless charging system for 800 V electric vehicles with integrated PFC-buck-IPT control

  • 期刊论文

  • 发表日期：

    2026年2月10日

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  • Chang-Min Lim,
  • Jeong-Won Yeom,
  • Seung-Min Chung,
  • Il-Oun Lee

摘要

This paper presents the design and experimental validation of a 22 kW LCC–CCL wireless charging system (WCS) developed for 800 V electric-vehicle (EV) platforms. The proposed system integrates a three-phase power-factor-corrector (PFC), a dual-interleaved buck converter serving as the battery-management (BM) stage, and an inductive-power-transfer (IPT) converter within a unified control framework, enabling seamless operation across constant-current (CC), constant-power (CP), and constant-voltage (CV) charging modes. To ensure high-efficiency power transfer under wide load and misalignment conditions, an LCC–CCL compensation network is analytically designed to maintain zero-voltage switching (ZVS) and a constant-current characteristic at a fixed operating frequency of 85 kHz. A complete system model, including magnetic-pad design, impedance matching, and real-time coordination among the PFC, buck, and IPT converters, is established. A 22 kW prototype, implemented using 1200 V-class SiC devices, achieves 93.87% peak efficiency, a power factor above 0.985, and a total harmonic distortion (THD) below 4% across a 500–860 V battery-voltage range, even under Z1-class, 75 mm × 100 mm misalignment. Compared with existing 400 V or single-stage WCS architectures, the proposed platform demonstrates superior scalability and dynamic stability for next-generation WPT4 level high-voltage EV applications. Experimental results verify that the integrated PFC-buck-IPT control strategy provides a practical and efficient solution for future high-power wireless-charging systems.