Robust Optimization of a Wireless Power Transfer Coupler Against Manufacturing and Fabrication Tolerances

Résumé

The design variables are optimized to improve the overall performance of wireless power transfer (WPT) coils or couplers. However, failure to consider their uncertainties and tolerances will lead to variations in the performance targets of a WPT system and mass-scale production of couplers cannot afford performance variation from one coupler to another. Therefore, this paper proposes a stochastic-based optimization method to incorporate the uncertainties and tolerances of design variables into the optimization process to realize a robust WPT coupler. The proposed robust optimization methodology is compared with the existing deterministic optimization methodology to achieve reduced transmitter and receiver side current harmonics, maximum efficiency, and minimum leakage magnetic field. The results demonstrate that the design resulting from the robust optimization has 1.59% and 1.66% fewer harmonics distortion in the receiver and transmitter side currents compared to the deterministic optimization, along with coil-to-coil efficiency of 96.5% and leakage field of 7.4 μT measured 650 mm from the center of the coupler. Moreover, the fabricated coupler from robust optimization has a superior efficiency profile under load variations.

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