Optimal Design of Copper Foil Inductors with High Energy Storage Density Based on Genetic Algorithm

The energy storage inductor is the core component of the inductive energy storage type pulse power supply, and the structure design of the energy storage inductor directly determines the energy storage density that the power module can achieve. Genetic algorithm is used to optimize the structure parameters of rectangular section copper foil inductors, and the inductor energy storage density is taken as the objective function. The independent variables include coil radial turns, coil inner diameter, single-turn conductor height, single-turn conductor width, coil layer number, turn spacing and layer spacing. According to the current flow capacity of the energy storage inductor, the upper and lower boundaries of the above parameters are required, and the local optimization problem of single objective optimization was constructed. The high energy dense inductor has an energy storage density of 56.74 MJ/m3 and a total inductance of 501 μH. It was designed at 20 kA of bare coil. Based on Comsol simulation platform, the magnetic field distribution and calorific value of the designed energy storage inductor can be verified, which provides a reference for the design of power module.