An improved calculation of ferrite core loss for nonsinusoidal waveforms separates a flux trajectory into major and minor loops via a new recursive algorithm. It is highly accurate and outperforms two previous methods for our measured data. The only characteristics of the material required are the standard Steinmetz-equation parameters.

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Abstract-Existing advanced and powerful techniques for optimizing litz-wire winding designs are complex and usually require using multiple expensive software packages. A new CAD tool has been created to make advanced litz-wire design methods available to any designer through an easy-to-use web interface. The software performs two-dimensional field simulations and returns designs optimized considering cost and loss. It is shown that simple fullbobbin designs, compared to optimized choices, can result in much higher loss with almost no cost advantage or much higher cost with almost no loss advantage, whereas the optimization results provide a full range of choices providing the lowest loss at any given cost or the lowest cost at any given loss.