A High-Power Three-Phase Orbirect Inductive Coil Topology for Electric Vehicle Wireless Battery Charging

Wireless power transfer (WPT) has emerged as a key enabling technology for safe, reliable, and user-friendly electric vehicle (EV) charging. The current multi-phase coils have issues with non-uniform magnetic fields, high leakage flux, and poor misalignment tolerance. To address these issues this paper proposes a novel three-phase Orbirect coil topology using a hybrid curved-rectangular design, a stacked-overlapped configuration, and optimized ferrite-aluminium shielding. The proposed coil topology enhances magnetic field uniformity while suppressing edge flux concentration and parasitic leakage paths. To validate the proposed design finite-element simulations using ANSYS Maxwell is carried out. The each phase of the transmitter is excited with a 120° phase-shifted 85 kHz current to produce a rotating magnetic field. The proposed design shows better self-inductance robustness, mutual coupling balance, and much lower leakage flux than the conventional designs. The results from field-contour and vector flux analyses also validate the smoother flux trajectories and reduced localized hotspots. The coil shows high coupling uniformity, and low ripple in the transferred power, which is beneficial for next-generation EV chargers and dynamic charging systems. ... mehrOverall the proposed
three-phase Orbirect design is a compact, efficient, and scalable solution for high-performance WPT systems.