New electrical parameters extraction method based on simplified 3D model using finite element analysis

The purpose of this paper is the presentation of an electrical equivalent circuit for inductive components as well as the methodology for electrical parameter extraction by using a 3 D finite element analysis (FEA) tool.

A parameter extraction based on energies has been modified for three dimensions. Some simplifications are needed in a real model to make the 3 D finite element method (FEM) analysis operative for design engineers. Material properties for the components are modified at the pre-modeling step and a corrector factor is used at the post-modeling step to achieve the desired accuracy.

The current hardware computational limitations do not allow the 3 D FEA for every magnetic component, and due to the component asymmetries, the 2 D analysis are not precise enough. The application of the new methodology for three dimensions to several actual components has shown its usefulness and accuracy. Details concerning model parameters extration are presented with simulation and measurement results at different operation frequencies from 1 kHz to 1 GHz being the range of switching frequencies used by power electronic converters based on Si, SiC or GaN semiconductors.

This new model includes the high-frequency effects (skin effect, proximity effect, interleaving and core gap) and other effects can be only analyzed in 3 D analysis for non-symmetric components. The electrical parameters like resistance and inductance (self and mutual ones) are frequency-dependent; thus, the model represents the frequency behavior of windings in detail. These parameters determine the efficiency for the inductive component and operation capabilities for the power converters (as in the voltage boost factor), which define their success on the market.

The user can develop 3 D finite element method (FEM)-based analyses with geometrical simplifications, reducing the CPU time and extracting electrical parameters. The corrector factor presented in this paper allows obtaining the electrical parameters when 3D FE simulation would have developed without any geometry simplications. The contribution permits that the simulations do not need a high computational resource, and the simulation times are reduced drastically. Also, the reduced CPU time needed per simulation gives a potential tool to optimize the non-symmetric components with 3 D FEM analysis.