Coupled Electromagnetic and Thermal Simulation Method for a DC-DC Converter Inductor

This paper presents an FEA simulation approach in analyzing an inductor on both its electromagnetic and thermal performance. Based on the coupled field simulation method, DC and ripple currents in the coils of the inductor induce magnetic field in the ferromagnetic core. Heat is generated both due to Joule heating in the windings and due to hysteresis plus eddy current loss in the core, the latter of which can be estimated using the improved generalized Steinmetz equation in each finite element. In order to control the temperature of the inductor and shrink its volume, a liquid cooling system is introduced to extract the heat from the core and windings. The coupled model is capable of providing accurate prediction of both the electromagnetic and thermal performance of the inductor. In this paper, detailed modeling method is provided with explanations and the experimental validation, which serve as a guide for future design and development of DC chokes.