Magnetic Coupler Robust Optimization Design for Electric Vehicle Wireless Charger Based on Improved Simulated Annealing Algorithm

Fleets of autonomous vehicles including shuttle buses, freight trucks, and road sweepers will be deployed in the Olympic Village during Beijing 2022 Winter Olympics. This requires intelligent charging infrastructure based on wireless power transfer technology to be equipped. To increase the misalignment tolerance of a high-power wireless charger, the robustness of the magnetic coupler should be optimized. This paper presents a new type of unipolar coupler, which is composed of three connected coils in series. The dimensional configuration of the coils is analyzed by the finite element method. The characteristic parameters of the coil are identified with their influence on the self-inductance and coupling coefficient. An expert model is built, whose feasibility can be verified in the aimed design domain. Combined with the expert model, an improved simulated annealing algorithm with a backtracking mechanism is proposed. The primary coil can reach the expected characteristics from any starting parameter combination through the proposed optimization algorithm. Under the same conditions in terms of external circuit parameters, ferrite usage, and aluminum shielding, the offset sensitivity of the magnetic coupler can be reduced from 58.79% to 18.89%. A prototype is established, validating the feasibility of the proposed coil structure with the optimized parameter algorithm.