Design of highly compact short‐time duty power inductors for supercapacitor charging applications

Abstract

For medium‐voltage, large‐capacity, multi‐output supercapacitor charging applications, power inductors play an important role in filtering and energy storage. For a short‐time duty power inductor, the major design challenge is accurate transient thermal prediction, which goes beyond the scope of the empirical method. A transient thermal model that considers water‐cooling plates was constructed to predict thermal performance. On this basis, this study presents a novel multi‐objective optimisation design method, where the analytical method and the finite‐element method were combined through programming control to balance accuracy and efficiency. Furthermore, a short‐time duty 400 kW/182 A/2 kHz/15 kV power inductor prototype was designed and manufactured. Compared with the results of the 30‐minute thermal experiment, the calculation error is no >7.0%, which is significant for the accurate and highly compact design of the short‐time duty power inductor.

Minimum-Output-Current-Ripple Control of Current-Fed Three-Level Phase-Shift Full-Bridge Converter

“…According to the data in the table, under different output current ripple indexes, the MOCR strategy can reduce the value of the minimum output filter inductance by about 23%. According to the inductor multi-objective optimization design method studied in [32] and the parameters in Table 1, the output filter inductor is designed. Figure 12 shows the comparison of the volume and weight of the minimum inductance required by the two strategies corresponding to different output current ripple indexes.…”

“…Generally, core loss is calculated by loss separation theory and mainly includes hysteresis loss, eddy current loss, and other losses. According to the calculation formula of magnetic core loss derived in [32], combined with (17), the total loss of inductance can be calculated. Figure 13 shows a comparison of the output filter inductance loss with different parameters.…”

“…It can be seen from the figure that, under the same output current ripple index requirements, the MOCR strategy can reduce the loss of output filtering inductor by up to 29.31%, which improves the efficiency of the converter to a certain extent. magnetic core loss derived in [32], combined with (17), the total loss of inductan calculated. Figure 13 shows a comparison of the output filter inductance loss w ent parameters.…”