A light weight magnetic coupler structure for interoperability and robust misalignment with primary-side impedance tuning for wireless power transfer systems to electric vehicles

Wireless power transfer (WPT) technology is explored as a promising solution for electric vehicle (EV) charging due to its convenience and potential to overcome traditional charging limitations. This study aims to present a novel lightweight magnetic coupler design, square grid structure (SGS), specifically aimed at enhancing interoperability and robustness in the presence of misalignments for primary-side impedance tuning WPT systems adapted for EVs.

The proposed coupler design uses the finite element analysis method through ANSYS Electronics Desktop software for optimization. A comprehensive comparative analysis is conducted, focusing on critical magnetic parameters such as coupling coefficient (k), mutual inductance (M) and self-inductance (L) for different air gaps. Three other coupler designs, including circular, rectangular and DD configurations, are considered in the evaluation process. Additionally, the performance of the proposed coupler is assessed through misalignment tolerance in different directions, magnetic flux density (B), magnetic field strength (H), Energy density, Quality factor (Q) with mesh generation and thermal analysis using ANSYS Icepak design software.

The study presents findings from the comprehensive analysis, highlighting the performance of the proposed SGS coupler in terms of different key magnetic parameters, misalignment tolerance in different directions and various operational conditions. To verify the result for Practical implementation, MATLAB Simulink demonstrates a remarkable power transfer efficiency (PTE) of 94\%, exceeding alternative coupler designs. These findings emphasize the potential of the lightweight magnetic coupler to enhance the performance and practicality of WPT systems for EVs.

Although the study offers valuable insights into the proposed SGS coupler design, there might be restrictions due to their hardware design being complex compared to other couplers and particular operating circumstances or environmental elements that were not considered during the investigation. Future studies could investigate these areas, focusing more on the shielding method to provide a more thorough knowledge of the coupler’s functionality.

This work advances WPT technology by presenting a novel SGS coupler design, which provides a robust and efficient solution for EV charging. The suggested lightweight magnetic coupler’s novelty and value in addressing the growing need for sustainable transportation solutions are highlighted by the significant improvement of 94% PTE.