Optimizing Inductor Winding Geometry for Lowest DC-Resistance using COMSOL Multiphysics® with LiveLink™ for MATLAB®

H. Schneider[1], T. Andersen[1], J. D. Mønster[1], M. P. Madsen[1], A. Knott[1], M. A. E. Andersen[1]
[1]Technical University of Denmark, Lyngby, Denmark
Published in 2013

An optimization routine is presented to optimize a hybrid winding geometry for a toroid inductor in terms of the DC-resistance. The hybrid winding geometry consist of bended foil pieces connected through traces in a PCB. MATLAB® is used to create a GUI that visually plots the winding using input parameters such as core dimensions, number of turns, clearance between windings, and the winding angle of each segment of the winding. COMSOL Multiphysics® with LiveLink™ for MATLAB® is used to import the winding geometry from MATLAB and create a 2D finite element model to simulate the DC-resistance. Finally the winding configuration with the lowest DC-resistance is found by sweeping the parameters of the winding geometry and simulate and save the result in each step.