High Frequency Magnetic Component Winding Optimizing Design Based On Finite Element Simulation

Magnetic components are one of the most important parts in switching mode power supplies. In order to achieve best performance under the requirements of the system, such as the minimum volume, weight and loss, it is vital to optimize the structure of the initial design results of those magnetic components. As is known that a magnetic component generally consists of a core and a winding, therefore, there are two kinds of losses in magnetic components: core loss and winding loss. Improving the loss characteristic of the magnetic materials can reduce the core loss;while winding loss can be reduced through the proper arrangement of windings and the gap.In this project, high frequency effects and the typical 2D FEA (Finite Elenment Analysis) model of magnetic component windings in high frequency power supplies are briefly presented at first; the high frequency winding characteristics of inductors, flyback and forward converter transformers are discussed in detail. By FEA simulation, optimization of the winding structure is performed based on parameters from AP method. An optimization aproach of the magnetic component windings is proposed, which combines AP method and improvement by FEA(Finite Elenment Analysis) simulation. In magnetic field simulation, in order to study the high frequency characteristics of magnetic components, two methods are proposed: one is to obtain the fundermental frequency component through FFT of the transient simulation current waveform to analyze the eddy current; and the other is to use the transient simulation current waveform as the stimulation source during the analysis. Magnetic field simulation is performed on the main magnetic components in a 100w active clamped forward converter, and experimental results verfied what had been analyzed.