A New Optimization Method for Gapped and Distributed Core Magnetics in LLC Converter

LLC converter design optimization remains a challenging task for varying loads such as in battery chargers. There are numerous L-L-C combinations to choose from space that can satisfy the required voltage gains of application. An accurate magnetic model is essential optimally size passive components according application needs. This paper provides new tool gapped core magnetics optimize transformer and resonant inductor converters. Unlike conventional algorithms, proposed algorithm considers multiple distributed cores selects optimal flux density by minimizing penalty function includes power loss, cost volume using Big-Bang Big-Crunch Algorithm. The equations have been verified Ansys Maxwell Simplorer co-simulation environment 3700W 48V calculated loss compared with experimental results. For given L m xmlns:xlink="http://www.w3.org/1999/xlink">r pair 37.52 μH 9.38 μH, designed two-distributed cores, each one exhibiting magnetizing inductance 17.73 leakage 0.7 on EE422120 3F36 material. total transformers measured 12.44 W 3700 prototype switched at 350 kHz.