Custom High-Current Inductors for EV On-Board Chargers

An automotive electronics supplier was developing an on-board charger for an electric vehicle platform. The charger required a high-current power inductor for energy storage and current filtering, but the available installation space was limited by the vehicle's compact power-conversion housing.

During prototype testing, the original inductor showed increased temperature rise during continuous charging. The customer also found that the component's resistance and magnetic performance changed under different current conditions. A standard inductor could meet part of the electrical specification, but it did not fully match the target current, thermal environment, mechanical height, and cooling path of the OBC.

Golden Eagle reviewed the input and output voltage, rated current, peak current, switching frequency, target inductance, saturation requirement, DCR, maximum temperature, core structure, winding method, PCB footprint, and installation position. The engineering team developed a customized high-current inductor instead of selecting a standard model only by nominal inductance.

The inductor structure was optimized around the magnetic core, conductor cross-section, winding arrangement, terminal position, and heat-transfer path. A suitable low-DCR winding design can help reduce copper loss, but the final performance must be evaluated together with the switching frequency, current waveform, cooling structure, and surrounding components.

For automotive applications, temperature and mechanical reliability are as important as electrical parameters. The customer evaluated inductance, DCR, saturation behavior, RMS current, peak current, temperature rise, insulation, vibration resistance, soldering reliability, and long-duration charging. If the component is required to operate above 85°C, the exact temperature range, material selection, and validation conditions must be confirmed according to the final product design.

Golden Eagle supports custom inductors, transformers, coils, and wireless charging components for automotive and industrial applications. The company has 15 years of R&D and manufacturing experience, and suitable projects may receive prototype support within approximately 3–5 days. The actual sample time, production schedule, and quality results should be confirmed according to the approved drawing, inspection specification, and project records.

The customized inductor gave the customer a more suitable component platform for OBC development and helped the engineering team evaluate the relationship between DCR, current loading, temperature rise, and cooling. It also reduced the risk of selecting a component that fits the electrical specification but fails to meet the complete vehicle-system requirements.

When sourcing a high-current inductor for an EV on-board charger, buyers should provide the electrical schematic, input and output conditions, rated and peak current, operating frequency, target inductance, DCR limit, saturation requirement, temperature range, vibration conditions, PCB drawing, available height, cooling method, sample quantity, and estimated annual demand.

Golden Eagle provides OEM and ODM support for automotive power inductors, high-frequency transformers, common mode chokes, air-core coils, and other custom magnetic components.