Easy-to-use CAD tools for litz-wire winding optimization

Abstract

Existing advanced and powerful techniques for optimizing litz-wire winding designs are complex and usually require using multiple expensive software packages. A new CAD tool has been created to make advanced litz-wire design methods available to any designer through an easy-to-use web interface. The software performs two-dimensional field simulations and returns designs optimized considering cost and loss. It is shown that simple full-bobbin designs, compared to optimized choices, can result in much higher loss with almost no cost advantage or much higher cost with almost no loss advantage, whereas the optimization results provide a full range of choices providing the lowest loss at any given cost or the lowest cost at any given loss.