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Recently, maintenance applications around power lines have been actively studied. These applications usually supply power through magnetic energy harvesting(MEH) to devices around the power line. A major challenge for practical MEH is to overcome magnetic saturation, which can cause degradation of power density under a wide current range in the power line. In this paper, we propose a design methodology to harvest maximized output power by considering the saturation effect. To consider magnetic saturation, the output power model and the saturable magnetizing inductance model based on magnetizing current were comprehensively analyzed. Additionally, the critical point of saturation for the maximum harvested power was analyzed by considering different primary side current conditions. With the proposed design methodology, the accuracy and efficiency of the output model were verified with experimental results compared to the conventional model. To consider the real environment, a 150 kW class of AC resistor load bank was implemented to control the primary current from 0 to 100 A with power frequency of 60 Hz. Experimental results show that the proposed method can harvest an average power of 14.32 W on 70 A power line, which is an increase of 39.8 % compared with the conventional design method.

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