Interleaved resonant DC-DC with NPC inverter and MSVPWM control for advanced EV wireless charging

Abstract The use of wireless charging technology for Electric Vehicles (EVs) is gaining increasing significance due to its ability to charge batteries safely and conveniently without the need for physical connectors. This paper presents the design and implementation of the transmitter-side power conversion system for a wireless EV charging station. The proposed system architecture integrates a front-end Power Factor Correction (PFC) rectifier, an Interleaved Resonant DC-DC converter, and a three-level Neutral Point Clamped (NPC) inverter, providing a highly efficient and stable power transmission path for battery charging. The Interleaved Resonant DC-DC converter, designed with a Zero Voltage Switching (ZVS) mechanism, minimizes switching losses and enhances overall efficiency. Its operation under Constant Current (CC) and Constant Voltage (CV) control modes ensures smooth and reliable mode transition through an auxiliary controller incorporated alongside a conventional PI controller. The inverter stage adopts a Modified Space Vector Pulse Width Modulation (MSVPWM) strategy that significantly reduces Total Harmonic Distortion (THD) in both voltage and current waveforms, thereby maintaining compliance with power quality standards. The complete system’s performance has been evaluated through both simulation and experimental validation. MATLAB/Simulink-based analysis demonstrates stable converter dynamics with a regulated output voltage of 325 V and negligible transient disturbances during mode transitions. A 0.2 kW laboratory prototype was developed to confirm the simulation results using PIC24F16KA102 and FPGA-SPARTAN-7 controllers for power and switching signal generation, respectively. Experimental measurements indicate that the proposed Interleaved Resonant DC-DC converter achieved an efficiency of approximately 95.35% at rated load, which aligns closely with theoretical predictions. The three-level NPC inverter produced a 320 V output with voltage and current THD levels of 4.8% and 5.6%, respectively. A 2:1 air-core transformer designed for high-frequency operation (100–200 kHz) effectively transfers power to the EV receiver side. The influence of coupling coefficient and air-gap variation on transfer efficiency was systematically investigated, revealing an optimal separation distance of 10–20 mm. The overall results confirm the efficacy of the proposed design for high-efficiency wireless EV charging. Future work will concentrate on optimizing the receiver-side converters to further enhance system efficiency and dynamic performance.