A new winding design method for inductors and transformers

In this paper an optimal winding design of inductors and transformers with different winding types is presented. The winding design is implemented both with iterative algorithm and analytical expressions. The optimum thickness formula by Hurley is modified for the use at higher current harmonics and checked with numerical solutions. A design software tool with a graphical user interface is implemented to construct the windings of a medium-frequency transformer at minimal achievable winding loss intended for a three-phase dual-active bridge (DAB3) application. Measurements of the transformers have been performed at a DAB3 platform to compare the calculations of the design tool.