Estimating Leakage Inductance in High-Frequency Transformers Using an Artificial Neural Network and a Gray Wolf Optimizer-Based Hybrid Algorithm

The trend in the power electronics industry toward higher power density and efficiency has brought high-frequency transformers (HFTs) to the forefront of critical applications, including isolated DC–DC converters, electric vehicle chargers, and solid-state transformers. This paper focuses on the leakage inductance of HFTs and presents a systematic comparative framework that evaluates five surrogate modeling and hybrid optimization approaches for the rapid and accurate estimation of leakage inductance. A comprehensive parametric dataset was constructed, comprising 1210 finite element analysis simulations conducted via finite element analysis in the ANSYS Maxwell 2024 R1 environment, varying the number of winding turns, primary winding thickness, and secondary winding thickness of the HFT. All five methods were trained and evaluated on the same dataset under identical conditions. The comparative evaluation demonstrates that the proposed hybrid Gray Wolf optimizer–artificial neural network (GWO-ANN) framework achieved the highest prediction accuracy (R2 = 0.9832, MSE = 0.01780, MAE = 0.0935 µH) and the fastest convergence among all tested approaches. The generalization capability of the proposed model was confirmed through blind validation tests across six geometric configurations spanning the full range of the design space, yielding a maximum prediction error of 8.15% and an average error of 2.14%. The functional validity of the proposed parameters was further tested in a third validation layer using MATLAB/Simulink R2024b transformer circuit studies, demonstrating a theoretical efficiency of 96.06%. This three-layer validation approach proves both the parametric and functional reliability of the proposed framework for HFT designs.