Novel Technique for Shaped Planar Inductor Winding Optimization in Gapped Core Applications

AC-loss analysis in gapped-core inductor windings can be performed using finite element analysis (FEM) software with good results. The process however becomes very time consuming especially if the winding is shaped in the vicinity of the air gap. The lack of closed form solutions for optimization of shaped windings emphasizes the need for alternative techniques offering solutions quicker than running FEM-simulations for all the possible conductor arrangements. A novel technique for optimisation of shaped planar inductor windings is proposed in this work but should be applicable to larger low frequency power system components with minor adjustments. The flux density as a function of the distance from the air gap is estimated using a very simple model and the subsequent losses calculated using a first-principle method with good results. The simulated results are verified experimentally.