Topology optimization of DC-biased pot-type reactor using design sensitivity in steady state of electromagnetic field with magnetic nonlinearity

Abstract

Because reactors applied to electric vehicles are typically driven under a DC-biased current, a constant inductance property is required. When a high-performance DC-biased reactor is designed, the topology optimization (TO) is an effective design method owing to the high degree of structural change in the magnetic circuit. However, there exists no report regarding the TO method in the steady-state time domain with magnetic nonlinearity. In this paper, based on the time-domain adjoint variable method, a novel sensitivity analysis approach for the steady-state time domain with thorough consideration of the magnetic saturation is proposed. Through the proposed method, the TO of the iron core and winding structures in a pot-type reactor was carried out to enhance the DC-biased characteristics. Furthermore, the eddy current loss occurring on the aluminum plate installed outside the reactor was suppressed by the multi-objective TO. The interesting structure of a pot-type reactor that enhanced the DC-biased characteristics and reduced the eddy current loss on the outer conductor plate was also illustrated.