1. Introduction
With the rapid advancement of smart grid digitalization, online monitoring technology for high-voltage transmission towers and lines has become a core pillar for ensuring the safe and stable operation of power grids [
1]. As monitoring equipment operates continuously in complex high-voltage outdoor environments, achieving reliable and sustained power supply has emerged as a critical bottleneck for technological implementation [
2]. Current power supply solutions, such as solar energy and batteries, suffer from significant environmental susceptibility or high maintenance costs [
3]. Furthermore, strict insulation distance requirements between high-voltage and low-voltage sides preclude the direct application of traditional wired power supply methods [
4].
Studies have shown that the Domino Resonant Inductive Coupling wireless power transfer (DR-IPT) system, leveraging relay coil-based energy transfer and contactless power delivery, has emerged as the preferred solution for long-distance insulated power supply [
5,
6]. The technology’s core lies in embedding coils within insulator strings to establish an energy pathway from the high-voltage side to monitoring equipment [
7]. Research confirms that this topology, when integrated with insulators, does not significantly alter the original electric and magnetic field distributions, making it highly compatible with high-voltage transmission environments [
8,
9].
In recent years, researchers worldwide have conducted extensive research on domino insulator string coils: Cai et al. proposed embedding resonant coils within 110 kV composite insulators, simplifying the structure using PCB technology and passing high-voltage testing [
10]; Qu et al. designed a domino system based on PCB resonators, achieving effective energy transmission over a 1.14 m distance [
11]; Li et al. optimized single-layer uniformly spaced coils using a particle swarm optimization algorithm, achieving 85.94% transmission efficiency at 50 cm [
12]; Yazdi et al. addressed interference from external metallic objects (EMOs) by establishing corresponding circuit models and optimization methods [
13].
However, while the aforementioned research has laid the foundation for engineering applications, significant limitations remain. Existing designs predominantly rely on regular, closely wound solenoid coils [
14]; this uniform approach struggles to optimize the magnetic field distribution and coupling between the coils, thereby limiting the system’s overall power transmission capacity and efficiency. Theoretically, employing non-uniform pitch designs can effectively improve the magnetic field distribution, enhancing both power transmission capacity and efficiency while facilitating a more lightweight design [
15]. However, systematic modeling and experimental validation for such variable-pitch coils applied within domino insulator strings are still lacking.
Furthermore, computational models for key parameters such as resonance frequency and resistance of irregular structures [
16] have yet to be effectively integrated with the coupling characteristics of domino multi-coils, limiting further system performance optimization. Previous work can be broadly categorized into three streams in mutual inductance and ef-ficiency optimization for WPT relay chains. The first stream focuses on analytical and numerical methods for inductance characterization, including Neumann’s formula [
15], the Biot-Savart-based segmented current approach [
16], and FEM-assisted surrogate mod-eling. The second stream covers system-level optimization, such as adjusting relay coil spacing [
11], compensation network design [
17], and operating frequency selection to maximize transmission efficiency or output power under fixed coil geometries. The third stream addresses coil geometry optimization, including studies on pitch modulation in solenoid coils for general inductive power transfer and DD-type coil designs for biomedi-cal WPT [
15].
For a multi-stage domino relay chain, the critical coupling region for inter-stage en-ergy transfer is precisely the air gap between adjacent coils, which corresponds to the low-flux midpoint region of each coil. By redistributing the wire density in a non-uniform pitch pattern—concentrating turns at the axial ends where coupling to the adjacent relay coil is geometrically strongest—a variable-pitch geometry can actively shape the spatial magnetic flux distribution to maximize inter-stage mutual inductance within a fixed axial envelope. This fundamentally distinguishes it from conventional uniform-pitch designs, which offer no geometric degree of freedom for flux management once the total wire length and winding radius are fixed.
Against this backdrop, this paper proposes an optimization design scheme for non-uniform solenoid coils in insulator strings based on the elitist non-dominated sorting genetic algorithm (NSGA-II) algorithm [
18]. The core research approach is as follows: First, construct a parameter calculation model suitable for irregular solenoids [
16] to precisely determine the coil inductance (L) and distributed parameters under non-uniform structures, overcoming the shortcomings of traditional empirical formulas such as poor adaptability and high computational cost; Second, by integrating domino multi-coil transmission theory, a dual-objective optimization function is established with “maximizing transmission efficiency” and “maximizing output power” as targets, incorporating spatial dimensional constraints of the insulator string and high-voltage insulation clearances as boundary conditions; Finally, the NSGA-II algorithm is employed to obtain the Pareto front, identifying the optimal coil distribution scheme that balances efficiency and power. This enables precise layout of each coil turn on the insulator string, with experimental validation confirming the feasibility and superiority of this approach.
This work has systematically integrated a physics-accurate analytical model for var-iable-pitch inductance with a multi-objective optimization framework under the unique dual constraints of 66 kV insulator strings, namely strict creepage distances and rigid shed-to-shed spatial boundaries. This constitutes the primary research gap addressed by the present paper.
The specific contributions of this paper are summarized as follows:
- (1)
A novel numerical integration model based on segmented current analysis is devel-oped to accurately compute the self-inductance, mutual inductance, and AC resistance of non-uniform variable-pitch solenoid coils, achieving a calculation error below 5% across the full operational parameter space—a capability not achievable with conventional em-pirical formulas.
- (2)
This physics-accurate model is systematically integrated into an NSGA-II mul-ti-objective optimization framework specifically tailored for the dual constraints of 66 kV insulator strings, yielding a Pareto-optimal pitch distribution that simultaneously max-imizes transmission efficiency and output power.
- (3)
Experimental validation on a five-stage prototype confirms 85.73% transmission effi-ciency and 97.48 W output power, with errors of only 1.1% and 2.4% relative to theoretical predictions, demonstrating both the accuracy of the analytical model and the engineering feasibility of the proposed design methodology.
3. Theoretical Analysis of the Domino Unit WPT System
To evaluate the transmission performance of variable-pitch coils in a domino system, this paper establishes an equivalent circuit model based on mutual coupling theory. This model transforms complex electromagnetic field problems into circuit network problems, enabling rapid determination of the system’s current distribution, output power, and transmission efficiency by solving the KVL (Kirchhoff’s Voltage Law) matrix equations.
3.1. Equivalent Circuit Topology of the Multi-Coil Domino System
The system consists of a transmitter, multiple relay coils, and a receiver. To compensate for the inductive reactive power of the coils, a series-series (S-S) compensation topology [
19] is employed. This topology exhibits insensitivity to load variations and features capacitance values dependent solely on self-inductance and frequency, making it suitable for fixed-structure applications such as high-voltage insulator strings.
Figure 3 shows Schematic Diagram of Domino Resonant WPT System. The equivalent circuit of the system consists of three main sections. Loop 1 includes the power source, source internal and coil resistance
, transmitter coil
, compensation capacitor
, and the coil’s internal resistance. Loop
acts as the relay loop, comprising the relay coil
Li, compensation capacitor
Ci, and internal resistance
. Finally, Loop
represents the receiver loop, containing the receiver coil
, compensation capacitor
, internal resistance
, and the equivalent load resistance
RL.
3.2. Construction of KVL Matrix Equations
Based on KVL, the loop current equations are established for the
coil loops. Considering that the domino system features not only strong coupling between adjacent coils (
) but also weak cross-coupling between non-adjacent coils (
), the system impedance matrix equation can be expressed as:
where
is the operating angular frequency of the system. It should be noted that the self-impedance
and mutual impedance
jωMij are complex measures. Furthermore, to standardize the rigorous representation of complex quantities, the phasor input voltage
and phasor currents
are properly represented with dot notation.
is the self-impedance of the
-th loop, expressed as:
For the transmitter loop (), must include the internal resistance of the power source ; for other loops, is the internal resistance of the coil. is the mutual inductance between coil and coil .
3.3. Simplified Solution in Resonance State
To achieve efficient transmission, the optimization algorithm is configured to ensure that the system consistently operates in a fully resonant state. According to Equation (2), the inductive reactance and capacitive reactance of each circuit cancel each other out at this point:
3.4. Performance Metrics
After obtaining the RMS value of each loop current , the performance metrics of each candidate solution in the current iteration can be calculated and used as the objective function inputs for NSGA-II:
Output Power
: Defined as the received power obtained on the load resistance
.
This metric reflects the system’s power supply capacity for monitoring equipment and is one of the core objectives of optimization.
Transmission Efficiency
: Defined as the ratio of output power to the total input power of the system. The input power
is equal to the sum of the resistance losses of all loops and the output power.
The transmission efficiency expression is:
4. Modeling and Parameter Calculation of Variable Pitch Domino Coils
The fundamental novelty of the proposed numerical integration model must be highlighted. Traditional WPT optimization heavily relies on empirical formulas that are exclusively applicable to uniform, closely wound solenoids. These conventional models inherently fail to accurately capture the highly complex, non-linear magnetic field distributions generated by irregular structures. In contrast, the methodology developed in this study utilizes segmented current analysis to precisely compute the internal/external inductance and the spatial magnetic flux mapping of non-uniform, variable-pitch structures. This theoretical breakthrough breaks the geometric limitations of conventional WPT designs.
4.1. Geometric Characterization of Spiral Tubes
4.1.1. Physical Model Definition
The variable-pitch solenoid studied in this paper is defined as a cylindrical structure where the coil radius remains constant, but the pitch between adjacent turns changes with the axial position, resulting in a non-uniform wire distribution. Unlike traditional uniformly wound solenoids, variable-pitch solenoids possess greater geometric freedom. The physical model is constructed based on two primary assumptions. First, the geometric central axis of the coil coincides with the -axis, with the magnetic field analysis focusing primarily on the axial component . Second, the coil consists of turns, where the pitch of each individual turn serves as an independently adjustable design variable.
4.1.2. Parametric Equations of a Spiral Curve
To precisely describe the spatial morphology of a helical tube, a cylindrical coordinate system is established. For a multi-turn coil with radius
r, its spatial geometric trajectory can be described by the following parametric equations:
Geometric Configuration and Key Parameters of Coils with Fixed Pitch p is shown in
Figure 4. In the axial direction, the equation for a traditional uniform solenoid is
. However, for variable-pitch solenoids, the pitch
p is no longer a constant but a function that varies with the number of turns. This paper employs a discrete segmented description method, dividing the coil into independent pitch segments. The axial height increase in the
-th turn coil is determined by the local pitch
of that turn. The spatial geometric trajectory of the
-th turn coil can be described by the following piecewise parametric equation:
where
denotes the cumulative rotation angle. For the
-th turn of the coil, the range of
is defined as
.
The parameter
represents the initial axial height of the
-th turn, which is equivalent to the cumulative sum of the local pitches of the preceding
turns. This relationship can be mathematically expressed as:
4.1.3. Discretization of Pitch Distribution and Design Variables
To apply the geometric representation to the NSGA-II optimization algorithm, the continuous helical geometry must be discretized into a finite set of optimization variables.
Assuming the total number of coil turns is , the complete coil structure is uniquely determined by independent pitches: . Taking into account both the space constraints of the insulator skirt and the coupling requirements, this model sets the total number of turns for a single coil to 10. This choice was validated through a parametric sensitivity analysis for N ranging from 6 to 14. For N < 8, the total ampere-turn product is insufficient to sustain the requisite mag-netic flux linkage across the inter-stage air gap, causing the mutual inductance to fall be-low the threshold for effective resonant power transfer. For N > 12, using commercially available Litz wire (0.5 mm outer diameter including insulation), the minimum pitch constraint ≥ Dwire cannot be satisfied for all turns within the fixed axial height h of the insulator shed, violating both geometric feasibility and high-voltage creepage distance requirements. The N = 10 configuration maximizes the effective pitch design freedom while remaining fully compatible with the insulator geometry; sensitivity analysis con-firms that N = 10 yields near-optimal performance across the full TOPSIS-weighted objective space. To guarantee the convergence of the optimization process while satisfying geometric constraints, a set of dimensionless free variables, (), is introduced. The domain of these variables is constrained to the interval .
The actual pitch
for the
-th turn of the coil is calculated using the following normalization equation:
where
denotes the total axial length of the coil. This formulation guarantees that the sum of all individual segment pitches is strictly equal to the predefined total length, i.e.,
.
4.1.4. Geometric Constraints
In practical engineering design, the geometric parameters of variable-pitch coils are subject to strict physical size constraints. The following geometric constraints must be imposed during the optimization process:
Wire Diameter Constraint: To prevent wire overlap and potential damage to the insulation layer, the pitch of each turn
must be greater than or equal to the wire diameter
, which is expressed as:
Maximum Pitch Constraint: To ensure the continuity of the magnetic field and maintain sufficient coupling strength, the pitch of a single turn should not be excessively large. The upper bound is defined as half of the total coil length, which is expressed as:
Through the geometric representation described above, the physical morphology of the variable-pitch solenoid is transformed into a mathematical vector that can be directly evaluated by the optimization algorithm.
4.2. Calculation Model for Inductance and Mutual Inductance of Variable Pitch Helical Tubes
Due to the non-periodic axial geometry of variable-pitch helical coils, traditional inductance calculation formulas designed for uniform closely wound helical coils are no longer applicable. To achieve precise characterization of non-uniform structures, this paper employs a computational model based on current segmentation and magnetic field numerical integration. Unlike traditional empirical formulas limited to uniform solenoids, the fundamental novelty of our proposed numerical integration model lies in its ability to precisely compute the internal/external inductance and spatial magnetic flux of irregular, non-uniform variable-pitch structures using advanced segmented current analysis. This model decomposes the total inductance into internal inductance and external inductance components while accounting for the influence of the high-frequency skin effect.
4.2.1. Model Assumptions and Fundamental Definitions
To simplify calculations while ensuring engineering accuracy, the computational model is based on two primary physical assumptions. First, due to the dominance of the axial magnetic field, the calculation of magnetic flux primarily considers the axial component of the magnetic flux density, denoted as . Second, through geometric discretization, the continuous helical coil is approximated as an equivalent superposition of independent single-turn loops.
4.2.2. Calculation of Internal Inductance
The internal inductance is primarily generated by the magnetic flux within the conductor. Under high-frequency conditions, the current tends to concentrate and flow along the surface of the conductor (a phenomenon known as the skin effect), which consequently leads to a variation in the internal inductance [
16]. Defining the wire radius as
, the magnetic permeability of the material as
, and the skin depth as
, the internal inductance per unit length, denoted as
, is calculated by the following formula:
The total internal inductance, , is subsequently obtained by integrating this value along the entire length of the conductor.
4.2.3. Numerical Integration Method for External Self-Inductance
For non-uniform helical coils, traditional analytical formulas become inapplicable due to the irregularity of their geometric structure. Therefore, this model employs a numerical integration method based on the Biot-Savart law [
16], calculating inductance by determining the magnetic flux passing through a specific surface. This approach unifies the calculation of self-inductance and mutual inductance [
20].
Figure 5 shows Schematic Diagram of the Specialized Numerical Integration Surface for Magnetic Flux Calculation of Variable-Pitch Coils.During the specific calculation process, the helical coil is first discretized into
infinitesimal segments along the trajectory of the wire. The current
and the position vector
for the
-th segment are strictly determined by the parametric equations of the helical tube. Subsequently, the Biot-Savart law is employed to calculate the axial magnetic flux density,
, generated by all infinitesimal segments at an arbitrary point
in space. For point
P, the total magnetic field is obtained through the superposition of the fields produced by all
discrete coil segments, expressed as:
where
denotes the z-component of the magnetic field generated by the
i-th current element at point
P.
To accurately capture the magnetic flux generated by sparse or geometrically irregular coils, the conventional “transverse mid-plane” approximation is inadequate, as it fails to account for the strong magnetic field regions in the immediate vicinity of the wire under large pitch conditions. To address this, a specialized surface connecting the coil loop to its central axis is defined. For the -th turn of the coil, this surface is constructed by connecting the physical trajectory of the coil to its corresponding projected points along the central axis. For a variable-pitch cylindrical solenoid, the z-coordinate, , of an arbitrary point on this defined surface is calculated via linear interpolation based on its polar angle and the corresponding z-coordinate on the wire.
By discretizing the constructed surface for the
-th turn into a mesh grid, the single-turn magnetic flux
is obtained through the numerical integration of the axial magnetic field
over this surface:
Next, the equivalent single-turn inductance of the
k-th turn,
, is calculated utilizing the current,
, flowing through the central infinitesimal element of that specific turn, with the relationship:
By summing the equivalent inductances of all
N individual turns, the total external inductance of the solenoid,
, is derived (
). Finally, the overall inductance
L is defined as the sum of the internal inductance and the external inductance, calculated using the formula:
4.2.4. Calculation Model for Mutual Inductance ()
The method for calculating mutual inductance is very similar to the numerical integration method used in
Section 4.2.3 to calculate external self-inductance. It will not be repeated here.
In the Domino system, it is necessary to comprehensively compute the mutual inductance effects between all adjacent and cross-interval coils to construct the complete system inductance matrix
. This matrix directly serves as the input parameter for the KVL circuit equation system described in
Section 3.2:
4.3. Calculation of Internal Resistance in Variable Pitch Helical Pipes
The resistance of the coil is highly dependent on the operating frequency. Due to the skin effect, the coil resistance increases as the operating frequency increases. There exists a critical cutoff frequency, denoted as
, below which the skin effect can be considered negligible. This cutoff frequency is calculated utilizing the formula provided in [
20]:
where
and
represent the magnetic permeability and electrical conductivity of the coil material, respectively. The resistance per unit length of the coil can be evaluated using the equation detailed in [
20]:
where
denotes the skin depth of the conductor, and
denotes the electrical resistivity of the wire material.
4.4. Simulation Validation of Computational Models
To validate the accuracy of the proposed model, results are compared against those from full-wave electromagnetic simulation.
To quantitatively evaluate the degree of non-uniformity of the variable-pitch coil, the mean value
and standard deviation
of the pitch
for each turn are defined as follows:
Based on these parameters, the coefficient of variation in the pitch, denoted as
, is introduced as a dimensionless metric to quantify the degree of pitch variation:
Let
denote the self-inductance calculated by the proposed model, and let
denote the corresponding value obtained from simulation. The relative error rate for the self-inductance (
) is defined as follows:
Let
represent the transmission distance between two adjacent coils. Through comprehensive simulations, heat maps illustrating the distribution of the relative error rates
within the parameter space of
can be plotted (as shown in
Figure 6). By performing independent surface integration for each individual turn, this theoretical calculation method effectively addresses the issue of uneven magnetic field distribution caused by drastic variations in the pitch
. The simulation validation demonstrates that the error rates of the proposed analytical model in calculating both the self-inductance and mutual inductance of variable-pitch coils are consistently maintained below 5%.
It is worth noting that in a practical insulator string environment, the presence of metallic hardware (e.g., iron caps and steel legs) induces high-frequency eddy currents and a slight inductance shift, potentially leading to a decrease in overall transmission efficiency. However, comprehensive electromagnetic simulations (
Figure 7) confirm that these fittings do not significantly alter the primary magnetic field distribution. Since hardware-induced loss is not the primary focus of this study, the subsequent optimization model isolates the coil geometry as the core variable, leaving the electro-thermal co-simulation with hardware fittings for subsequent research.
To ensure computational feasibility during the multi-objective optimization process, two key assumptions were adopted. First, the model assumes the dominance of the axial magnetic field to streamline the numerical integration of the external inductance. While this represents an idealization of the fringing effects, the localized error is well-compensated, as evidenced by the <5% overall parameter accuracy confirmed through 3D FEM analysis. Second, the current analytical model does not explicitly calculate hardware-induced eddy current losses. It must be acknowledged that in actual 66 kV field deployments, the intersection of the high-frequency alternating magnetic field with the metallic components of the insulator string will inevitably generate eddy currents and parasitic thermal losses. Based on supplementary 3D electromagnetic co-simulations incorporating realistic material properties, these metallic components are projected to cause a 5% to 10% degradation in the overall system transmission efficiency. This provides a transparent baseline for future practical engineering deployments.
7. Conclusions
This paper addresses the challenge of power supply for high-voltage transmission tower monitoring equipment by proposing an optimization scheme for variable-pitch domino wireless power transfer coils based on insulator strings. By constructing a computational model of the electromagnetic parameters of non-uniform solenoids and combining the NSGA-II algorithm with TOPSIS decision-making, this study successfully resolves the inherent trade-off between maximizing transmission efficiency and maximizing output power. Experiments confirm that the optimized variable-pitch coil outperforms traditional uniformly wound designs in all key performance metrics, achieving a maximum transmission efficiency of 85.73% and a maximum output power of 97.48 W in a five-stage cascaded system. This study provides a reliable, efficient, and stable approach with significant engineering application value for contactless insulated power supply in complex high-voltage environments.
Nevertheless, several limitations of the current study should be acknowledged to guide future research. First, the number of turns per coil is fixed at
N = 10 throughout the optimization; while this choice is justified by the insulator geometry constraints (see
Section 4.1.3), treating
N as a discrete decision variable in future work could potentially yield further performance gains. Second, hardware-induced eddy current losses from the metallic iron caps and steel legs of the insulator string are not incorporated into the NSGA-II fitness evaluation function; based on supplementary electromagnetic co-simulations, these components are expected to cause a 5–10% efficiency degradation in actual field deployments, and integrating a lightweight hardware loss surrogate model into the optimization loop is an important direction for future work. Third, the experimental prototype is limited to a five-stage relay chain, corresponding to a standard 66 kV insulator string; scaling to higher voltage classes (110 kV or 220 kV), requiring 7–15 cascading stages, will introduce more prominent non-adjacent cross-coupling effects, necessitating higher-order model complexity and increased optimization dimensionality. Fourth, the current model assumes constant wire resistivity at a nominal temperature; in enclosed insulator environments subject to thermal accumulation under continuous full-load operation, the increase in winding resistance could further reduce efficiency, motivating future thermal-electromagnetic co-optimization work.
Beyond the validated 66 kV application, the scalability of the proposed domino WPT framework to ultra-high-voltage networks, such as 110 kV or 220 kV, warrants further discussion. Scaling to these voltage levels typically necessitates an increase in the number of relay stages to approximately 7–15. A primary technical challenge in such extended chains is the exponential decay of overall transmission efficiency, driven by the accumulation of parasitic resistances and enhanced leakage flux across multiple air gaps. To address this issue, future research will focus on expanding the NSGA-II optimization to a higher-dimensional variable space to actively leverage or suppress cross-coupling between non-adjacent coils.