A Field Enhancement Integration Design Featuring Misalignment Tolerance for Wireless EV Charging Using LCL Topology

This article proposes a magnetic integration design for EV wireless power transfer (WPT) systems, where the compensation and transmitting coils overlap one on top of the other to share the ferrite layer without any decoupling consideration. The magnetic field generated by both the compensation and transmitting coils are exploited to transfer power. To this end, a compensation method is proposed to enable magnetic field enhancement without any reactive power flow between the compensation and the transmitting coils, and to achieve input zero phase angle and constant current output. In addition, an efficient finite element analysis-based coil optimization algorithm is proposed to improve the coil misalignment tolerance on the horizontal plane, in which a reversely connected inner coil is used to stabilize the system output under misalignment conditions. Analytical and simulation results confirm transmission flux density enhancement and reduced leakage field characteristics of the proposed coil design. Finally, a scaled-down WPT prototype is built and tested to verify the performance and effectiveness of the design. The proposed design achieves 91.17% efficiency and misalignment tolerance up to 200 mm in any XY-direction while maintaining the power transfer and its efficiency. The results of this work provide insights into magnetic integration design of high-order compensation topologies featuring higher compactness, less ferrite usage, magnetic field enhancement, and misalignment tolerance for WPT systems.