Geometric form Factors-Based Power Transformers Design

A novel model for power transformers design is presented in this paper. It is based on the use of two Geometric Form Factors (GFFs) - namely KF and Kc- associated to magnetic cores shape and material. The transformer non-linear magneto-electro-thermal model is solved numerically to identify the commercial magnetic core whose GFFs allow minimizing the size of a custom transformer, under given power loss and thermal specifications. The model provides the boundaries of the acceptability region in the plane KF-KC enabling a straight comparison among multiple feasible solutions compliant with given design constraints. The case study presented in the paper concerns the design of a custom power transformer for an isolated DC-DC converter.