Double-Layer Coils Design for 11 kW Wireless Power Transfer

The design of a wireless power transfer system with double rectangular coils for 11 kW power transfer is considered. System modeling and numerical calculation of the system parameters are described. Coils are made from available Litz wire, which has a smaller than necessary diameter for the required power. Thus, a setup with double layer coils was developed, which resulted in a modified design. Starting from a system consisting of coupled coils, as suggested by the standard for wireless power transfer Level 3 in class Z1, different coil and ferrite shield layouts were tested in numerical simulations, and their parameters were calculated. The prototype was constructed based on the simulated model with the best results and properties. Numerical results were verified by laboratory measurements, and a successful power transfer at 11 kW was achieved.