Thermal Design of High-Energy-Density Wound Components

• Published in: IEEE transactions on industrial electronics (1982) Vol. 58; no. 9; pp. 4096 - 4104
• Main Authors: Wrobel, R., Mellor, P. H.
• Format: Journal Article
• Language: English
• Published: New York IEEE 01-09-2011; The Institute of Electrical and Electronics Engineers, Inc. (IEEE)
• Subjects: Accounting; Anisotropy; Computational efficiency; Finite element method; High-energy-density inductor; Inductors; loss separation; Mathematical analysis; Thermal analysis; Thermal design; Thermal measurements; Windings
• ISSN: 0278-0046; 1557-9948
• DOI: 10.1109/TIE.2010.2093485

This paper presents an alternative computationally efficient approach to the thermal design of compact wound components. The method is based on the use of anisotropic lumped regions within 3-D thermal finite-element analyses. The lumped regions replicate the multimaterial composites used in the construction of wound components. Material data for these lumped regions are obtained experimentally, accounting for the thermal anisotropy. Input loss data for the analysis were derived by combining electromagnetic finite-element iron loss calculations with experimental ac copper loss correlations. The technique is applied to a design of a high-energy-density filter inductor. Thermal measurements from prototype inductors are compared with the theoretical predictions showing a good agreement.