Electromagnetic Fields Calculation and Optimization of Structural Parameters for Axial and Radial Helical Air-Core Inductors

To improve the current density distribution and electromagnetic performance of air-core inductors, a structural optimization method combining back-propagation(BP) neural network and genetic algorithm(GA) is proposed for the study of axial and radial spiral multi-winding inductors. The Monte Carlo method was used to extract the structural size samples of the inductors, and the training dataset was obtained through the finite element calculation of electromagnetic fields. Based on BP neural networks, nonlinear mapping models between the inductance value, volumetric inductance density, current distribution non-uniformity coefficient, and inductor structural parameters were constructed. A sensitivity analysis of the inductor inductance value affected by the structural parameters was conducted using the Sobol index calculation. Using the current distribution non-uniformity coefficient as the fitness function and the volumetric inductance density as the constraint condition, a genetic algorithm was applied to globally optimize the structural parameters of the inductor. The optimization results were verified through a finite element comparison. The results show that, under the requirement of satisfying the volumetric inductance density, the current distribution non-uniformity coefficient of the Axial Helical Inductor (AHI)-type inductor was reduced by 4.57% compared with the best sample in the sampling, while that of the Radial Helical Inductor (RHI)-type inductor was reduced by 5.33%, demonstrating the practicality of the BP-GA joint algorithm in the structural optimization design of inductors.