Cross-Material Magnetic Core Loss Prediction via Operating-Condition Matching and Partial Optimal Transport

Power magnetic materials are characterized on the sinusoidal and triangular waveforms that excitation hardware conveniently produces, whereas deployed converters expose cores to trapezoidal, PWM-shaped flux trajectories, so loss models must predict exactly where their training data are thinnest. The final test of the MagNet Challenge embeds a deliberately extreme instance of this characterization-deployment mismatch: for material D, trapezoids form 16.4% of the test set but only 1.4% of the training set. The 95th-percentile relative error, hereafter p95, of the best submission, built on sequential transfer learning, stalled at 15.9%, the worst among the five materials. This paper shows that the obstacle is missing information under covariate shift rather than class imbalance, and that the missing support can be borrowed from sibling materials instead of being extrapolated. Controlled experiments first refute the imbalance reading: four standard remedies fail, and raising the trapezoidal share to the test-set level degrades accuracy further. The proposed material-identity support transfer, MIST, then trains one 2784-parameter predictor jointly on all five challenge materials. Material identity enters through feature-wise linear modulation, or FiLM, the scarce material's true-label loss is reweighted, and material D receives no fine-tuning, so that the bias of its trapezoid-free training set is never re-installed. MIST lowers the five-seed material-D p95 from 20.39+/-2.03% to 12.38+/-0.92% and the trapezoidal-class p95 from 37.4+/-8.8% to 15.16+/-1.69%, surpassing the best submission with one-sixth of its parameters and no fine-tuning stage; removing material identity at matched capacity inflates the error by an order of magnitude. These results argue that scarce materials should be characterized jointly with their siblings.

Magnetic core loss originates in the hysteresis loop: the energy dissipated per excitation cycle equals the loop area, and frequency, temperature, and waveform shape set the loss by reshaping the loop geometry. Most existing models let these conditions act only on a terminal scalar - empirical equations fold them into fitted exponents, and data-driven predictors append them to encoded features - so no intermediate hysteresis representation remains for the conditions to reshape. This paper proposes CAHR-Net, a condition-adaptive hysteresis reconstruction network that injects the operating conditions where they physically act. It preserves the interpretable chain from flux density waveform to magnetic field reconstruction, loop-area integration, and power loss estimation, and uses feature-wise linear modulation to inject frequency, temperature, and waveform statistics into the intermediate reconstruction representation. A matched large-batch training protocol based on AdamW, cosine scheduling, and a staged reconstruction-to-power-loss objective is also reported, because the modulation pathway takes effect only within it. On the MagNet final A-E material protocol, CAHR-Net attains an average p95 relative error of 6.89% with only 1874 parameters, the lowest among all compared methods, together with a lower worst-material p95 than the strongest black-box solution at about 48x fewer parameters; it reduces the average p95 of the physical reconstruction backbone from 7.47% to 6.89% and the p95 of material D, the most difficult material, from 16.40% to 14.87%. Ablation and condition-slice analyses attribute the improvement to the coupling of physical loop reconstruction, structured condition modulation, and the matched optimization trajectory.

Magnetic components in high-frequency, high-power-density converters are increasingly driven by non-sinusoidal flux-density waveforms with fast transitions, minor-loop operation, dc bias, and temperature variation. Under these conditions, steady-state core-loss formulas and single-valued material curves cannot fully capture transient magnetization responses. This work proposes the Physics-Informed Hybrid Neural Operator (PI-HNO), a compact material-specific neural model with B-H energy-consistency regularization for core-loss-oriented transient magnetization prediction. Given the measured B(t)-H(t) history, the input B(t) series over the prediction interval and operating-condition information, PI-HNO predicts the H(t) series and the corresponding reconstructed B-H trajectory. The model integrates a local recurrent branch for boundary-state representation and rate-dependent response evolution with a Preisach-inspired global branch that extracts waveform-level hysteresis context. Evaluation on the MagNetX transient database using material-specific models for 14 ferrite materials demonstrates that PI-HNO achieves a compact trade-off between sequence accuracy and B(t)-H(t) energy consistency, with the mean and 95th percentile B(t)-H(t) energy consistency errors of 1.92% and 7.60%, respectively, using only 4777 trainable parameters per model. Ablation studies further demonstrate that the local, global, and energy-aware regularized components provide distinct contributions to transient magnetization prediction.