Design and Optimization of Magnetic Core Structure for Dynamic Wireless Charging Systems

Dynamic wireless charging technology can realize charging while driving, which can effectively increase the driving range of electric vehicles. Magnetic coupler is a critical part of the system, which always have the problems of low coupling coefficient and high cost. In this paper, a coupling structure design method is proposed to achieve a balance between high coupling coefficient and cost. Firstly, the transmission characteristics of the coupler is analyzed, and the main influence factors of the system performance are obtained. The characteristics of the E-E type magnetic core were analyzed, and the structure was optimized to obtain an optimized E-type magnetic core, referred to as the novel E-type core in this paper. The thickness and spacing of the magnetic core were optimized to reduce the variation of the coupling coefficient and manufacturing costs. The effectiveness of the proposed method was verified through simulation and experimental results, with a 71.2% increase in the coupling coefficient compared to the case without a magnetic core and an 80.88% cost reduction.