High frequency inductor proximity loss calculation with 3D finite element analysis considering non-sinusoidal current distortion

This paper describes a 3D finite element (FE) based method to calculate the proximity losses for magnetic components in power conversion system. The proximity loss is the main concern of copper loss which causes ac losses in the winding. The FE model is built based on the definitions of the geometries, meshes, materials, electric circuits, boundary conditions, load conditions, as well as the characteristics of the wire. The total proximity loss is the sum of the power losses of each element calculated with the power loss density function using the obtained nodal flux densities via finite element analysis (FEA) at the given load condition. Owing to a detailed model with all the geometric parameters and thus the flux leakage and end-winding effects can be considered, this FEA approach can predict the flux density more accurately. In addition, non-sinusoidal current is analyzed to calculate the actual power loss in current distortion condition. Experimental tests have been implemented to validate the method. The approach is capable of calculating the energy consumption in power converter for efficiency approvement and energy management.