Magnetically-coupled resonant wireless power transfer systems (WPTs) operating in the megahertz range is well-suited for mid-range transmission of moderate power levels. The class-E power amplifier (PA) is attractive for the MHz WPT applications due to the high-efficiency and soft-switching properties. However, since the output power and the efficiency of the class-E PA strongly depends on the output load, any change in the mutual inductance of coupling coils, which leads to the PA load variation, results in a dramatic loss in the overall performance of WPT system. This paper provides a comprehensive design analysis to analytically and numerically mimic the PA behavior to conveniently adapt any variation of the input impedance of the coupled coils to the PA optimum load using a T-type matching network. An equivalent circuit analysis followed by the design theory for the class-E PA, coupled coils, and the T-network has been presented. For validation purposes, the class-E PA implemented by the cost-effective IRF640 MOSFET was first fabricated and its performance was measured for different load values. The PA efficiency and output power was measured as high as 96.7% and 25.8 W, respectively, for the optimum load value of 9 Ω, which was closely predicted from the theory. A 1 MHz WPT system was then built for the operating range up to 27 cm, showcasing its behavior in presence and absence of the proposed T-type matching circuits at two arbitrary 10 cm and 25 cm distances between the coupling coils; the input impedance of the WPT system for those separation distances were 4 Ω and 0.2 Ω, respectively. Results demonstrate power transfer efficiencies of 88% and 15% at distances of 10 cm and 25 cm with the T-network, respectively, improved by 33% and 12% to the non-matching state, respectively. The overall DC output power achieved using a full-bridge rectifier are 21.9 W and 6.8 W at 10 cm and 25 cm, respectively.
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