Low-Loss Design of Magnetic Material and Operating Conditions via a Physics–Data Dual-Driven Core Loss Model

Accurate core loss evaluation is essential in the design of magnetic components. Core loss is critically influenced by excitation waveform, temperature, and magnetic material; therefore, we develop a waveform equivalence coefficient, a temperature polynomial, and an electrical conductivity term to revise the Steinmetz Equation and propose a physics–data dual-driven core loss model across materials and operating conditions. The waveform equivalence coefficient achieved 100% waveform classification, and temperature polynomial modification reduced the mean square error by an order of magnitude. Using three-way analysis of variance (ANOVA), we measured the individual and synergistic impacts of the three key factors on core loss. The waveform exerts the greatest individual influence while waveform and material, as a combination, exerts the greatest synergistic influence. Given the discovery that Material 1 demonstrates a property transition point under triangular waveform, the dual-objective optimization result indicates that using Material 1 under operating conditions of 90 °C, 501,180 Hz frequency, 0.0047 T peak flux density, and a triangular excitation waveform enables the magnetic component to achieve minimum core loss with maximum transmitted magnetic energy.