Fast Optimization of High-Frequency Transformer Using Orthogonal Test with Analytical Model

High-frequency transformers are extensively applied in various power electronics converters, and their design and optimization are crucial. Existing multi-objective optimizations achieve excellent performance by placing high algorithmic demands on engineers, conducting tens of thousands of iterations, and utilizing customized components. This paper proposes a fast optimization approach by using orthogonal test, which is highly suitable for general engineering applications. The proposed method allows for the use of common parts to reduce cost, overcomes the optimization limits caused by the usage of standard components, and completes the optimization process with only a few simple arithmetic operations. The effectiveness of the method is verified by improving the efficiency of a 2.4kW high-frequency transformer from 97.7% to 99.1%.