Design of Magnetic Concrete for Inductive Power Transfer System in Rail Applications

Inductive power transfer (IPT) systems are transforming railway infrastructure by enabling efficient, wireless energy transmission for electric locomotives equipped with Li-ion batteries. This technology eliminates the need for overhead power lines and third rails, offering financial and operational advantages over conventional electric propulsion systems. Despite its potential, IPT deployment in rail applications faces significant challenges, including the fragility of materials (i.e., ferrite and Litz wires), thermal management during high-power transfers, and electromagnetic interference (EMI) on the transmitter side. This study discusses several factors affecting IPT efficiency and introduces magnetic concrete as a durable and cost-effective material solution for IPT systems. Magnetic concrete combines soft ferrite powder with water and coarse aggregates to enhance magnetic functionality while maintaining structural strength comparable to conventional concrete. Its durability and optimized magnetic properties promote consistent power transfer efficiency, making it a viable alternative to traditional ferrite cores. A comparative study has been performed on non-magnetic and magnetic concrete (with 33% ferrite powder) using both permeability tests and finite element analysis (FEA). The FEA includes both thermal and electromagnetic simulations using Ansys Maxwell (v.16), revealing that magnetic concrete can improve temperature management and EMI mitigation, and the findings underscore its potential to revolutionize IPT technology by overcoming the limitations of traditional materials and enhancing durability, cost-efficiency, and power transfer efficiency. By addressing the challenges of fragility, thermal management, and shielding of the unique coil topology design presented, this study lays the groundwork for improving IPT infrastructure in sustainable and efficient rail transport systems.