A Multi-Objective PFC Boost Inductor Optimal Design Algorithm Based on Pareto Front

In this study, the inductor optimization design is performed by applying the Pareto optimization technique. As environmental problems emerge, the electric vehicle market is expanding, and accordingly, volume reduction and high efficiency of the onboard charger (OBC) are required. An OBC consists of a PFC stage and a DC/DC stage. The inductor is a major component in a converter and affects the volume and efficiency of the entire converter system. However, reducing the volume of the inductor leads to an increase in loss due to an increase in the change in flux density. Therefore, it is important to derive a suitable design for the target between the two parameters in the trade-off of loss and volume. This paper introduces the optimal design algorithm for boosting inductors of PFC converters in terms of volume and loss. Volume and loss are difficult to compare with each other, making it difficult to set weights. Therefore, Pareto optimization was applied which can be selected according to the needs and purposes of the decision-maker, without weighting as an optimization method. Through a series of procedures of applying Pareto optimization to the inductor design, several optimal inductor designs can be derived. At this time, the optimal designs become a set of designs in which the loss does not decrease without an increase in volume, or the volume does not decrease without an increase in loss. A designer can select a design with an appropriate volume and loss that meets the purpose of the design or preference. Therefore, through the proposed method, the inductor can be flexibly designed according to the target of the application. The proposed algorithm is applied to the interleaved totem-pole bridgeless boost PFC converter, to review its effectiveness. As a result, several inductor designs are derived in the search space, and various optimal designs are visualized through the Pareto Frontier. This facilitates comparative analysis of various inductor designs and helps designers select reasonable inductors. The validity was verified by selecting one of the obtained optimal inductor designs and driving the experiment with the resulting inductor.