Optimization of Coreless PCB Coils Based on a Modified Taguchi Tuning Method for WPT of Pedelec

The printed circuit board (PCB) winding coil offers advantages such as small size, high precision, high repeatability, and low cost, making it conducive to the miniaturization of electronic equipment and a popular choice in wireless power transmission systems. This paper aims to clarify the correlation between induction parameters and inductive capabilities using the orthogonal array of the modified Taguchi method for Pedelec applications. The conventional Taguchi method typically achieves only local optimization; however, this paper considers practical application conditions and combines experimental data to establish the initial values of the orthogonal array, thereby achieving global optimization. Additionally, the tuning process of the Taguchi method replaces physical experiments with simulations, enhancing optimization speed and reducing hardware implementation costs. The performance index for the proposed modified Taguchi tuning method is selected as a combination of the quality factor (Q) and coupling coefficient (k) to minimize AC resistance and improve system efficiency. To validate the proposed method, the designed coils were implemented and tested in a WPT system based on S–S compensation with a half-bridge topology. The experimental results demonstrate that the optimized PCB coil parameters derived from the proposed tuning method accurately validate the method’s effectiveness and accuracy. From the measured results with the proposed modified tuning method, the system efficiency is increased by 43.87% and the system transmitting power is increased by 28.51%.