Determining Relation between Size of Polarized Inductive Couplers and Nominal Airgap

Inductive power transfer (IPT) is gaining popularity across a wide range of battery charging applications like biomedical, consumer electronics and electric vehicle (EV) charging. One of the major challenges in designing IPT charge pads is determining the optimal physical sizes of the magnetic couplers resulting in efficient power transfer and low cost of materials. In EV applications, it is especially difficult due to the variation in nominal air gap, required power levels associated with different vehicle classes, and charging locations that may be encountered. This paper aims to determine the relationship between optimal coupler sizes and the nominal air gap of an IPT system. Finite element analysis (FEA) is used to model the electromagnetic behavior of the magnetic couplers. A multi-objective optimization framework is built to reveal the Pareto fronts which show the trade-offs between the power transfer efficiencies and the coupler power densities at different air gaps. This method is applied on polarized double-D (DD) couplers for a 5 kW IPT system at different air gaps. Analyzing the power densities of the Pareto Optimal designs an approximate relation between optimal pad sizes and the air gap is derived. Results show that there is an exponential relationship between the optimal coupler sizes and the nominal air gap.