Integrated magnetic and thermal design of high-frequency magnetics with interfaces to optimise power electronic Systems

Host

Hitachi

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Client & task

Seven Games Company

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Objectives

High-frequency magnetics are central to compact and ultra-efficient power converters, but their performance is fundamentally limited by thermal constraints. As switching frequencies increase and core materials evolve, the thermal environment becomes increasingly complex: losses concentrate in small volumes, hotspots emerge quickly, and parasitic effects (like proximity losses or dielectric heating) strongly affect temperature distribution.
Achieving simultaneous optimisation of electromagnetic and thermal behaviour is therefore crucial. This demands digital workflows that combine high-fidelity FE simulations, material models from WP2, and AI-based optimisation to explore vast design spaces efficiently. Furthermore, system-level reliability aspects—partial discharge (PD), EMI/EMC, or packaging-induced stresses—must be considered from the start. This project creates a unified design framework to push high-frequency magnetics to unprecedented power densities while ensuring robust thermal performance and reliability.

Objectives 1

Development of innovative design methods based on FE simulations and AI methods for electro-thermal codesign of HF magnetics to maximize power density while efficiently managing heat dissipation.

Objectives 2

Employment of methods and models from WP2 to create specific electric simulations for reliability (partial discharge), thermal or EMI/EMC (component parasitic capacitance) simulations.

Objectives 3

Produce an accurate and accelerated time-domain simulation model applying the numerical magnetic component models from WP2 for integration with power electronic circuits, enhancing system efficiency, power density and reliability.

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Expected Results

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19.7%
New design methodologies and design tools for HF magnetic components that optimise power density and thermal management, paving the way for more reliable and efficient magnetic components
19.7%
A robust and accurate time-domain simulation model tailored for power electronic circuits, enabling more precise and reliable system performance predictions.
19.7%
high power density magnetic transformer prototypes (higher than 15 kW/kg).

Sed fringilla gravida lorem, id rhoncus justo egestas sed. Nulla sagittis vel ante sit amet neque non tellus interdum tincidunt eget eu odio. Awesome!

- Brian Green, CEO of Seven Games

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