Optimization of ferrites structure based on integrated coil design for wireless EV charger

The miniaturization and lightweight of wireless EV chargers are of great significance. For the inductive power transfer system based on double-sided LCC compensation topology, an integrated design is proposed in which all the magnetically coupled components and compensation components are integrated into the aluminum shell of wireless chargers. For the quadrature arrangement of DD coils, including the main inductor and compensation inductor, the magnetic field distribution of the magnetic coupler is analyzed, the influence of ferrite thickness is studied, and the optimization method of ferrite shape is presented. Under the condition that the magnetic coupling effect is very little affected, the weight of ferrites in the proposed optimized scheme is reduced by 47% compared with the initial scheme. In the prototype experiment, the DC-DC efficiency reached 95.38% when the output power of the system was 6.93 kW.