Multi-physics design of high-energy-density wound components

Abstract

In this paper a computationally efficient high-fidelity multi-physics design tool applicable to E-core power inductors is developed. The tool is composed of 2-D electromagnetic and 3-D thermal finite analyses coupled to models for inductor core and winding loss. The models are fully parametrically defined and appear as a black-box problem which can be used to perform parameter studies or design optimisation. For example, the influence of strip or edge wound rectangular conductors on ac loss generation and thermal performance can be evaluated or inductor designs which satisfy a given specification can be identified. The tool is demonstrated by the design and experimental test of a high-energy-density filter inductor for an automotive application.

Exploiting cloud computing in the multi-physics design and optimisation of electromagnetic devices

“…2, [17]. The models are fully parametrically defined and appear as a "black-box" problem which takes a set of design parameters, D p , containing geometric, material, boundary condition and specification data as input and returns a high-fidelity approximation of the electromagnetic, loss and thermal behaviour of the inductor as output.…”

“…An adiabatic boundary condition is applied to each surface with the exception of the base where a fixed temperature boundary condition is applied to emulate the cold-plate. The model incorporates slot liner and calibrated interface gaps in order to better represent a real world device and improve temperature predictions, [1], [17], [22]. Due to symmetry only one quarter of the inductor is modelled.…”

“…In this paper, the use of cloud computing to complement an existing multi-physics power inductor design workflow is presented, [17]. The implementation of the computationally efficient power inductor model is described along with its role in the current workflow.…”

Additive manufacturing of shaped profile windings for minimal AC loss in gapped inductors

“…6, results in a DC loss increase of 39 %, however, the AC loss is reduced by 75 % compared to the baseline design and the losses are distributed more evenly over the conductors with a standard deviation of 1.8 W as opposed to 40.8 W in the baseline case. The distribution and magnitude of the losses influence the temperature profile and hot-spot location of the winding, [23]. Hence, the (VW, VH) winding could result in a lower peak to average temperature and improved reliability.…”

“…In this study, the inductor is modelled using a parametric 2D FEA model, [23], which includes the effects of winding eddy currents and non-linearity of the core permeability. The conductor dimensions are varied automatically using a Particle Swarm Optimisation (PSO) algorithm with an objective of minimising AC loss at a fixed frequency of 400 Hz, Table I.…”