Inductor Design of Interleaved Totem-Pole Bridgeless Boost PFC Based on Pareto Optimization

A Pareto-based inductor design algorithm is proposed to optimally design the boost inductor of the PFC converter. With the expansion of the electric vehicle market, high power density is required for Onboard chargers (OBC). Considerations about volume and loss are needed to improve the power density of the OBC. The inductor is one of the large volume elements in the converter. Various variables are involved in the design of the inductor, and the volume or loss varies depending on each design variable. This paper proposes a multi-purpose optimal inductor design algorithm for designing the optimal inductor in terms of volume and loss. At this time, the inductor is targeted at the boost inductor of the power factor correction (PFC) converter that makes up the OBC, and the Pareto optimization technique is used as the optimization method. This paper sets the design variables as cores, the number of cores in parallel, and the cross-sectional area of the copper wire, and generates a Pareto optimal solution set that meets the specifications and constraints of the PFC. Designers can choose a design that suits their purposes from a number of optimal designs. By applying the proposed algorithm to the interleaved totem-pole bridgeless boost PFC, an inductor Pareto optimal design is performed, and experiments verify the effectiveness of the algorithm.