Rapid Design of Litz Wire Through Inverse Surrogate Modeling

The practical litz wire design needs either experimental characterization or 3D numerical simulation. Both of these methods are time and cost consuming. In order to improve efficiency, this paper presents an inverse surrogate process to design the litz wire for a given frequency range. The method builds a fast inverse surrogate between frequencies and design parameters. The surrogate is built from existing designs or simulations. Once the inverse surrogate is established, the optimum design at a given frequency can be obtained immediately. The obtained design is then refined using a frequency correction process to fix frequency misalignment. The method is applied to a five-strand litz wire optimization problem to demonstrate its efficiency.