Research and Design of a Concave Solenoid Wireless Power Transmission System with High Misalignment Tolerance

To address the issue of significantly reduced coupling coefficient and limited transmission efficiency in traditional flat solenoid magnetic couplers within wireless power transfer (WPT) systems under horizontal lateral offset conditions, this paper proposes a design method for a concave flat solenoid coil magnetic coupler for engineering applications, aiming to achieve high misalignment tolerance. An equivalent model of the LCC/S compensation circuit is established, its output characteristics are analyzed, and the parameter configuration method for its resonant elements is derived. Secondly, from the perspective of winding arrangement, the mechanism by which the coil winding method, turn spacing, and port concavity angle affect the uniformity of magnetic field distribution and the retention rate of the coupling coefficient is analyzed in detail, and corresponding parameter trade-off and optimization methods are proposed. Subsequently, a simulation model of multiple configuration magnetic couplers is established based on Ansys/Maxwell, comparing the magnetic field distribution and coupling coefficient variation of different structures under horizontal offset conditions. The results show that the concave structure with a non-uniform arrangement and a port concavity angle of 30° can still maintain a high coupling coefficient and stable transmission performance under a maximum horizontal offset equal to 60% of the corresponding transmitter-side characteristic dimension. To achieve lightweight and integrated design, the receiver is designed with a flexible printed circuit board (FPC) coil structure, meeting the miniaturization and high power density requirements of low-to-medium power portable devices. Finally, a 100 W experimental prototype was built. Experimental results show that within an offset range of ±15 mm on the X-axis and ±30 mm on the Y-axis at the receiver, the system output voltage fluctuation is controlled within 4%, and the maximum transmission efficiency reaches 87.3%. These results verify the feasibility and practical applicability of the proposed magnetic coupler with high misalignment tolerance.