A Systematic Design Methodology for the Receiver Structure in EV Dynamic Wireless Charging System

Magnetic coupler is a complicated energy exchange device in dynamic wireless charging (DWC) system for electric vehicle (EV). Due to the large air gap, the current design of magnetic coupler relies on finite element methodology and lacks systematic design concept. This paper proposes a semi-analytical design methodology for the receiver structure in the DWC magnetic coupler. The methodology has a clear design concept and divides the design process into four parts: determination of specification and constraints, calculation of electrical parameters, design of receiver’s geometric parameters and verification of system performance. The methodology can supply design guidelines and recommended range for the principal geometric parameters of the receiver by establishing the analytical-functions between the geometric parameters (such as the sizes of receiver coil) and the transmission characteristic parameters (such as output power, power density and lateral displacement). During the design process, the proposed methodology basically relies on analytical calculations, and solely a few finite element simulations are required throughout, which solves the problems of lengthy design time and unclear design concept in conventional finite element design methodology. Finally, a design instance based on the proposed methodology is given and a 30kW prototype was built for experimental verification.