Design and Performance Analysis of Misalignment Tolerant Charging Coils for Wireless Electric Vehicle Charging Systems

In order to design a high efficiency Wireless Electric Vehicle Charging (WEVC) system, the design of the different system components needs to be optimized, particularly the design of a high-coupling, misalignment-tolerant inductive link (IL), comprising primary and secondary charging coils. Different coil geometries can be utilized for the primary and the secondary sides, each with a set of advantages and drawbacks in terms of weight, cost, coupling at perfect alignment and coupling at lateral misalignments. In this work, a Finite Element Method (FEM)-based systematic approach for the design of double-D (DD) charging coils is presented in detail. In particular, this paper studies the effect of different coil parameters, namely the number of turns and the turn-to-turn spacing, on the coupling performance of the IL at perfect alignment and at ±200 mm lateral misalignment, given a set of space constraints. The proposed design is verified by an experimental prototype to validate the accuracy of the FEM model and the simulation results. Accordingly, FEM simulations are utilized to compare the performance of rectangular, DD and DDQ coils. The FEM results prove the importance of utilizing an additional quadrature coil on the secondary side, despite the added weight and cost, to further improve the misalignment tolerance of the proposed inductive link design.

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