Terrace-Shaped Core Design Method for Inductive Power Transfer System Considering Uniform Magnetic Flux Distribution

Inductive power transfer (IPT) has attracted a lot of attention, and it has a tendency toward high-power applications. However, the problem of nonuniform magnetic flux distribution exists and is unsolved in IPT systems, which will cause unbalanced core loss and local heat, lowering the system's stability. Therefore, a novel terrace-shaped core made of nanocrystalline flake ribbon (NFR) is proposed and investigated to balance the magnetic flux in the core for curved double-D couplers. Unlike merely increasing the core thickness in the center area, the terrace-shaped NFR (T-NFR) can realize uniform magnetic flux distribution and balanced temperature along the core. The feasibility and effectiveness of the T-NFR core are verified on a 1 kW IPT system with a transmission efficiency of 92.13%. The experiment results show that the maximum temperature in the center area can be mitigated from 55 to 41.6 °C, exhibiting a 51.2% improvement in temperature discrepancy. Meanwhile, the weight of the proposed T-NFR core is only 47.2 g, obtaining a 62.27% reduction compared to the traditional bar-shaped core with uniform thickness.

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