Comparative Study on Plate Arrangements of Hybrid-Field DD Couplers for Efficient Wireless Charging of Mobile Robots

This paper proposes a Hybrid-Field DD (HFDD) coupler designed for wireless power transfer (WPT) in mobile robots within smart manufacturing environments, utilizing a dual-coupling mechanism of magnetic and electric fields. The proposed coupler integrates Double-D coils for vertical magnetic field concentration with a split metal plate structure for enhanced electric field coupling in a compact, low-profile design. To evaluate the electromagnetic performance and the impact of inevitable eddy current interference, two distinct configurations—Front Plate Arrangement (FPA) and Back Plate Arrangement (BPA)—are analyzed through both theoretical modeling and 3D full-wave simulations (HFSSs). The comparative results demonstrate that the FPA model reduces the peak induced current intensity by 56.23 A/m compared to the BPA and achieves a peak leakage magnetic field intensity of 1.12 A/m, which is 28% lower than the 1.56 A/m observed in the BPA, offering a superior solution for suppressing leakage magnetic field and contributing to robust coupling stability. The high consistency between the proposed analytical methodology and numerical simulations underscores the theoretical robustness of the HFDD structure, establishing a clear design framework for efficient power transfer in robotic applications.