An Alternative IPT Pickup Controller for Material Handling Using a Current Doubler

Inductive power transfer systems deployed in material handling have traditionally used parallel-tuned (current-sourced) boost regulators to independently control and regulate the load on each secondary. This paper evaluates the current doubler as an alternative parallel-tuned secondary controller within this application to better match the current and voltage requirements in the secondary resonant tuning network in high-power applications. This enables designs that enable the secondary magnetic pickup to achieve a smaller profile and fit within typical space constraints of material-handling vehicles. This paper presents the design approach needed for this regulator and compares its operation and performance against a traditional boost controller using both the simulation and the measurement of two built 5-kW secondary regulators. The current doubler naturally achieves a lower output ripple due to its interleaved switching and is found to have a comparable efficiency to the boost controller but requires slightly more components.