Power Inductor Optimization Using Non-linear Magnetization Characteristics

The inductor design plays a significant role within the power converter design as it is a major contributor to the overall size, weight, and power loss of the system. Optimal design of an inductor through iterative approaches can prove to be challenging because of the parameter inter-dependence. This paper discusses the design of power inductors through the use of the Genetic Algorithm (GA) including the non-linear magnetization characteristics of the core material. The inductor design is suitable for high power electric vehicle and hybrid electric vehicle applications. The optimization evaluates iron powder cores and ferrite cores for operation in a bi-directional boost converter rated at 60 kW. The evaluation show the potential benefit of non-linear designs by considering various frequencies and number of interleaved phases.