A step-up DC-DC converter such as an interleaved boost converter, is required between the battery pack and the traction inverter to boost the available voltage to the required high voltage level. However, in the EV’s majority of the space is taken by the battery pack and the remaining space needs to be distributed among motors, inverters and onboard chargers. Thus EVs incur distinct packaging constraints to adjust the electrified powertrain. A new structural inductor geometry is proposed and modelled using a new high-fidelity magnetic equivalent circuit (HFMEC) model that was derived and applied for the design of this geometry which reduces the inaccuracies associated with the traditional magnetic equivalent circuit (MEC) modelling. The model proved to be capable of evaluating the flux and current characteristics much quicker and with less computational cost. The proposed inductor geometry is then implemented with a three-phase interleaved converter to evaluate the performance.
