Optimization Design of DC Electromagnet Coil Considering the Power Consumption and Cost

Electromagnet coil is mainly composed of enameled wire which wound on the coil skeleton, and the function is to convert the electrical signal into a magnetic signal, which is a very important electric-magnetic conversion element. When designing the electromagnet coil, usually only the total winding turns and winding inner diameter can be calculated, and the specific design parameters such as the diameter of copper wire, paint layer thickness, and winding turns of each layer can only be selected through experience, indicating that the design method should be improved. In addition, the unreasonable design parameters will seriously affect the power consumption and cost of coil, so it is highly necessary to improve the optimization design method. In order to solve the above problems, an optimization design method for DC electromagnet coil is proposed in this paper. This method simultaneously takes into account both power consumption and manufacturing cost, and can achieve the optimal matching of design parameters. In this paper, the structure of electromagnet coil is introduced, and the theoretical calculation model of resistance is improved first. Then, according to the expected requirements of electromagnet coil for steady current, the optimization design method is proposed and the optimal design parameters are obtained. Finally, the effectiveness of the proposed optimization design method is verified by the test platform of electromagnet coil. The results show that the electromagnet coil designed by the optimization design method fully meets the expected requirements. The relevant research results can provide reference for the optimization design of electromagnet coil, which has a certain engineering practical value. © 2024 Institute of Electrical Engineers of Japan and Wiley Periodicals LLC.