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) systems for electric vehicles (EVs). Due to the large air gap, the current design of the magnetic coupler relies on finite-element (FE) methodology and lacks a systematic design concept. This article proposes a semianalytical 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 the 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 FE simulations are required throughout, which solves the problems of lengthy design time and unclear design concepts in conventional FE design methodology. Finally, a design instance based on the proposed methodology is given and a 30-kW prototype was built for experimental verification.