Robust Optimization Design of High-Frequency Transformer Considering the Effects of Core Cutting

The integration of soft magnetic tapes enables the miniaturization, high-efficiency, and high-frequency operation of high-frequency transformers (HFTs), thereby meeting the demands of modern electrical applications. However, the core cutting process can cause localized damage to the tape along the cross-sectional area, resulting in a decrease in magnetic permeability and an increase in core losses near the edges. Consequently, the presence of core cutting introduces numerous unavoidable uncertainties, such as parameter variations, that can affect the performance of HFTs. In response to these challenges, this paper presents a robust optimization design method for HFTs. This method incorporates the manufacturing errors introduced during the core cutting process into the transformer design optimization. This approach accurately predicts the optimization objective uncertainty due to edge degradation, thereby enhancing the reliability of HFTs.