Optimization of Custom Ferrite E-Core-Shaped Transformers for Power Loss and Volume Reduction Using Pareto Front Analysis

This paper introduces a generalized parameter notation for the design of custom Ferrite E-cores with various dimensions by utilizing the oblong ratios of the window area (ξ) and the oblong ratio of core effective area (δ). This notation provides a framework for the customization of custom shape transformer cores. A simple and fast method to calculate the Losses/Volume Pareto front for custom E-cores is proposed, considering the material saturation limit. The study reveals that planar shapes are Pareto efficient, when close to the thermal limit where the power density is highest. Other shapes can also be Pareto efficient but with lower power density. The comparison of the custom solutions to commercial E-cores shows a reduction of 49% in volume with the same power losses for the ratios of ξ = 1 and δ = 6.3 on the Pareto efficient curve. Alternatively, another custom design on the Pareto front curve achieves a reduction of 63% in power losses for the same volume for the ratios of ξ = 0.5 and δ = 4.3.