Optimization of Coil Geometry and Pulsed-Current Charging Protocol with Primary-Side Control for Experimentally Validated Misalignment-Resilient EV WPT

The widespread commercialization of wireless chargers for electric vehicles generally suffers from one main problem, which is the perfect alignment between the two coils, leading to a decrease in mutual inductance, which causes a drop in magnetic coupling and even a failure to transfer power. To address this persistent problem, this work proposes a comprehensive and integrated method for optimizing the coils and control architecture for reliable and safe battery charging. To address the challenges of a complex, nonlinear design space and the need for misalignment-tolerant geometries, we employ a memetic algorithm (MA) that hybridizes Particle Swarm Optimization (PSO) for broad global exploration with Mesh Adaptive Direct Search (MADS) for precise local refinement. This combination effectively avoids poor local solutions—a limitation of standalone PSO or GA approaches reported in recent studies—while efficiently converging to coil geometries that maintain strong magnetic coupling under misalignment. After the coils have been designed, electromagnetic validation is tested using finite element analysis (FEA), which allows the magnetic field distribution to be evaluated, as well as the coupling coefficient under different scenarios of misalignment and variation in the air gap between the ground side and the vehicle side. At the same time, a comprehensive control strategy for the primary side of the system has been developed. This control method ensures power management on the primary side, enabling system interoperability for charging multiple types of vehicles, as well as reducing vehicle weight for greater range. All this is combined with an innovative pulsed current charging method, chosen for its advantages in terms of thermal stability, ensuring safe and efficient recharging that is mindful of battery health. Simulation and experimental validation demonstrate that the proposed framework maintains stable wireless power transfer and achieves over 87% DC–DC efficiency under lateral misalignments up to 100 mm, fully complying with SAE J2954 alignment tolerance requirements.