Design Method for the Coupled Pad of a Wireless Power Transfer Electric Vehicle Charger

This work proposes an optimisation method for the coupled pads of an electric vehicle wireless power transfer (WPT) charging system. The method utilises a design flowchart to sequentially optimise key design parameters, significantly reducing computational time compared to brute-force optimisation approaches. A novel aspect of this method is the inclusion of a manufacturer’s willingness-to-pay for efficiency increase, highlighting the importance of including economic factors in WPT system design. This willingness-to-pay parameter serves as the primary constraint guiding design decisions, ensuring that the resulting design not only meets efficiency and power density targets but also remains economically feasible for manufacturers. The paper assesses the current state-of-the-art performance of coupled pad systems in both industry and academia, establishing targets to ensure competitiveness in system design. The method illustrates that current benchmarks can be surpassed in simulation, assuming an optimised willingness-to-pay. As such, it solidifies its competitiveness in coupled pad design research. Furthermore, the effectiveness of the design flow is demonstrated through both extensive simulation and an experimental setup, validating its practical applicability. This approach not only addresses the key technical challenges in WPT system design but also holds promise for advancing the accessibility and affordability of the technology, thereby contributing to the global efforts towards sustainable transportation solutions. The proposed method’s flexibility allows for extrapolation to other industries beyond electric vehicles, enhancing its relevance and applicability in diverse contexts where wireless charging is a viable option.