Optimized Modeling Process for Air Core Reactors using Finite Element Analysis

Abstract

This paper presents an optimized modeling process for air core reactors using a finite element-based software and with the deployment of this process, proposes a correction for proximity-effect losses calculation method. A 2-D equivalent geometry method is proposed and the validation is performed by running a full factorial design of experiments, screening four design parameters of coils: winding diameter, winding height, number of strands and strand diameter, as these parameters significantly affect air core reactors' two main design characteristics: inductance and power losses. The results of the finite element simulations are compared to the results of analytical calculations using formulations well known by the literature. The optimized modeling provides very good consistency with the analytical calculations and allows for a huge reduction in the simulation time in the finite element simulations as it is not necessary to model every and each strand of the coil.