Research on the Magnetic Integration of Inductors for High-Power DC Transformers—A Case Study on Electric Roadways

With the growth of renewable energy, electrified highways can efficiently utilize green energy such as solar and wind for EVs, promoting sustainable transportation and carbon reduction, and accelerating the transition to a greener future. For high-power DC/DC converters in electrified roadways, a lightweight and compact design is crucial, but inductors limit progress. Therefore, this study focuses on the magnetic integration of DC/DC chopping inductors. It first selected and optimized the decoupled magnetic integration form, initial electromagnetic parameters, and core sizes based on circuit topology and device specifications, using core loss and thermal rise models. Then, it determined the optimal winding turns ratio according to the air gap and magnetic resistance ratio, obtaining the final design with insulation considered. The design was verified through finite-element simulation, prototype manufacturing, and testing, and an improved optimization with interleaved parallel control was proposed. Results indicate that magnetic integration reduces the inductor’s volume by 7.93% and footprint by 38.62%, facilitating the lightweight and compact design of relevant magnetic components. With interleaved parallel control, the integrated inductor’s volume can be reduced by 19.74%, significantly decreasing the volume and mass of the chopping inductor.