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In this paper, an optimization method of toroidal core-based Hybrid common-mode chokes (HCMCs) for the design of an Electromagnetic interferences (EMI) filter is proposed. A dedicated algorithm is developed using MATLAB to characterize compact HCMCs that exhibit effective CommonMode (CM) chokes with optimized leakage inductances by systematic variations in the winding patterns and geometric dimensions of their magnetic cores. It takes into consideration the physical limitations of these components as well as the constraints related to the design of EMI filters. The proposed algorithm allows through a small computational task to propose a variety of configurations for optimal HCMCs. Finite element method (FEM) simulations are conducted on the HCMCs to extract their CM and leakage inductances. The results are compared with those calculated analytically and yield a good match. The performances of optimized HCMCs are evaluated through their implementation in the designed filter. All the cases of HCMCs including the smallest one allow the EMI filter to easily qualify a power converter to an electromagnetic compatibility (EMC) standard.
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