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

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.