Design for 500-kW WPT Coils Based on Coil Geometry Search Including Physical Dimensions

High-power wireless power transfer (WPT) systems are required for rapid charging of electric vehicles. In a high-power WPT, discharge between windings and magnetic saturation in the transmission coils inhibit power amplification. Hence, conventional coil design methods with fixed physical dimensions cannot be applied to the design of a high-power WPT system. Therefore, in this study, a new dimensional design for copper pipe coil is proposed. In the proposed design method, flexibility is introduced in the physical dimensions of the transmission coil and a parametric analysis is performed to determine a combination of dimensions that can transmit the target power. A copper pipe coil for 500-kW power transmission is dimensionally designed using the proposed design method, and the design is validated via analysis and experiment.