A Novel Multilayer Rectangular Coil Design for Mitigating Misalignment Challenges in Electric Vehicles Wireless Charging System

ABSTRACT Wireless power transfer (WPT) for electric vehicle (EV) charging suffers from efficiency losses due to coil misalignment, limiting its practical deployment. This paper proposes a novel multilayer rectangular (MLR) coil with an optimized stacking configuration, integrated with a ferrite core and aluminum shielding, to enhance magnetic coupling and minimize EMI. Finite element analysis (FEA) using Ansys Maxwell, validated against literature coils such as circular, rectangular, and, DD coils, shows that the MLR coil achieves a 32.63% higher coupling coefficient than circular coils at a 200 mm air gap and 87.24% higher coupling under lateral misalignment. With an LCC‐Series compensation network, the system achieves 96.23% DC‐to‐DC efficiency at 22 kHz, maintaining performance across 300 mm lateral and 20° angular displacements. Simulation in PSIM shows an output power of 3.3 kW for a 160 mm air gap under perfectly aligned conditions. To experimentally validate the proposed magnetic coupler, a laboratory‐scale 120 W prototype was developed. The prototype is intended to verify the electromagnetic behavior and misalignment characteristics of the proposed MLR coil rather than demonstrate full‐power EV charging performance. This advancement contributes to safer, faster, more reliable, and more efficient, misalignment‐tolerant static and dynamic EV charging. To validate the proposed MLR coil design, a laboratory‐scale wireless power transfer (WPT) system was developed that delivers approximately 120 W. The setup operates with a 36 V DC input voltage and an inverter switching frequency of 22 kHz. The MLR coil's enhanced characteristics, including superior mutual inductance and coupling coefficient, were confirmed through experimental tests. The influence of varying distances on power transfer efficiency and system performance was evaluated, demonstrating robust operation under misalignment conditions. Measured results closely align with theoretical expectations, underscoring the coil's potential for efficient and reliable EV charging applications.