This study presents the development, simulation, and hardware implementation of a 48 V, 1 kW mid-range wireless power transfer (WPT) platform for autonomous guided vehicle (AGV) charging in industrial applications. The system uses an LCC-S compensation topology, selected for its ability to maintain a constant output voltage and deliver high efficiency even under load variations at a typical coil distance of 15 cm. It can also operate at different distances by adjusting the compensator circuit. A proportional–integral (PI) controller is implemented for current regulation, offering a practical, low-cost solution well suited to industrial embedded systems. Compared to advanced control strategies, the PI controller provides sufficient accuracy with minimal computational demand, enabling reliable operation in real-world environments. Current adjustment can be dynamically carried out in response to real-time changes and continuously monitored based on the AGV battery’s state of charge (SOC). Simulation and experimental results validate the system’s performance, achieving over 80% efficiency and demonstrating its feasibility for scalable, robust AGV charging in Industry 4.0 Manufacturing Settings.

This research paper introduces the remaining useful life prediction of lithium batteries operating at 48 V, 100 Ah on the cellular telecommunication substation with the load supply current conditions 1C rate at 100% DOD. According to the prediction technique, a 100-cycle of experimental results of actual discharge time are used to create the equation by using the curve fitting technique. Finally, the obtained results can estimate the battery lifetime and identify the time which will be able to supply the battery's load if the battery is operated under any conditions.

This paper presents the design and calculation of wireless power transfer (WPT) integrated with the Hamiltonian Control Law. The proposed controller demonstrates greater effectiveness in terms of system stability and precise energy control, as compared to the commonly used PI controller in industrial applications. The proposed prototype has been built for assessment in both simulation and implementation, with a rated output power of 500 W and 48 V. The load-independent compensating topology, such as the LCC-S resonant tank, is used to transmit power wirelessly through an air core. Finally, in the last stage, the Hamiltonian Control Law with state observer is applied on the dc-to-dc buck mode converter to control the battery current and overall system. Apparently, the charging current can be precisely regulated to a specific value.