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This paper aims to overcome the lack of methodologies for optimizing the volume of bulky low-frequency inductors that the authors came across with when working on the design of hybrid active power filters. Sound work was published concerning this well-known technology, but it became evident that the mentioned optimization topic was left unaddressed.

Using the Lagrange multipliers optimization method combined with the electromagnetic laws of inductor design, it was possible to establish a new design method to determine the optimal solutions that fulfil any given scenario of specifications. In other words, it is now possible to obtain the inductor’s geometric and electric parameters that not only satisfy the system’s electromagnetic requirements but also lead to smaller, lighter or economical solutions.

A generalized set of equations was obtained to facilitate the calculations of all the inductor-building parameters. As expected, these equations take as inputs the inductor’s required inductance, its maximum current and the desired resistance, but also a customizable cost function. The later cost function will optimize the inductor’s volumes of copper and iron and can be settled, among other purposes, for minimizing the total weight, volume or cost.

All the mathematical expressions to obtain the general optimal solutions are given as well as practical graphics for the three above-mentioned optimization criteria. Using these charts, the reader will be able to obtain by simple inspection the optimal solutions for a large, generalized universe of intended specifications.