Design optimisation and trade-offs in multi-kW DC-DC converters

Scoltock, James; Calderon-Lopez, Gerardo; Wang, Yiren; Forsyth, A.J.

doi:10.1109/ecce.2016.7855029

Cited by 6 publications

(4 citation statements)

References 15 publications

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“…The strategy is based on the algorithm proposed in [17] for integer optimization problems, extending the procedure in [18] for the optimization of single and two-phase boost converters. The equations which were modified for this study are included in this section.…”

Section: Design Optimization Strategymentioning

confidence: 99%

Power-Dense Bi-Directional DC–DC Converters With High-Performance Inductors

Calderon-Lopez

Scoltock

Wang

et al. 2019

IEEE Trans. Veh. Technol.

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An investigation is described into the optimization of multi-phase, high power, bi-directional DC-DC interleaved converters suitable for Electric Vehicle (EV) applications. Two dual-interleaved topologies were considered initially for the optimization, the main difference being the magnetic devices: either discrete inductors (DI) or an Interphase Transformer (IPT). The comparison used a comprehensive multi-objective design optimization procedure for an 80 kW case study. High performance inductors comprising a split-core structure and dual-foil windings to reduce losses, and a 180 C core, enabled the DI to be competitive with IPT in terms of power density and efficiency. The optimized designs are validated experimentally with an 80 kW bi-directional SiC DC-DC converter, achieving a power density of 31.4 kW/L and specific power of 15.7 kW/kg. The study is then extended to 100-kW three and four-phase interleaved topologies.

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Section: Design Optimization Strategymentioning

confidence: 99%

Power-Dense Bi-Directional DC–DC Converters With High-Performance Inductors

Calderon-Lopez

Scoltock

Wang

et al. 2019

IEEE Trans. Veh. Technol.

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“…Passive filter inductors occupy a significant amount of space in motordrives which ultimately pays the price of having increased weight, volume and overall system losses. These components are widely used in power generation and motor-drive systems, including automotive and aircraft applications that contribute a substantial portion of converter's weight and volume, potentially larger than 50% of the mass [1][2][3][4].…”

Section: Introductionmentioning

confidence: 99%

Novel Permanent Magnet Synchronous Motor With Integrated Filter Inductor, Using Motor's Inherent Magnetics

Khowja¹,

Gerada²,

Vakil³

et al. 2021

IEEE Trans. Ind. Electron.

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A close functional and structural integration of passive elements is required to improve the power density of motor drives. Such power dense motor drives are prerequisite in aerospace and automotive applications. This paper presents a permanent magnet motor with integrated filter inductor, which not only eliminates inductor losses but also removes its associated weight and volume. The motor with integrated filter uses motor's inherent magnetics in order to use it as a filter inductance instead of adopting an external inductor option, which is traditionally placed outside the motor. A vector-controlled model, taking modulation and switching effect into account, has been developed by using MATLAB/Simulink tool. To experimentally validate the concept of the motor with integrated filter inductor, the winding connections of an existing motor are modified. The comparative analysis, between the traditional and integrated motor drive systems, is carried out in terms of magnitude of switching component, total system losses, weight and volume. The total losses in the motor with integrated filter are reduced by 34.2% at 2100rpm and 3Nm load, when compared to the motor with traditional filter inductor, whereas, its weight and volume in the motor with integrated filter inductor is eliminated completely.

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“…To capitalize fully on modern component technologies such as nanocrystalline cores and wide-bandgap devices, converter design optimization has become increasingly important [1], balancing multiple design objectives such as power density and efficiency [2][3][4]. These techniques are reliant on multi-domain component models, including electrical, magnetic, and thermal behavior.…”

Section: Introductionmentioning

confidence: 99%

Rapid Thermal Analysis of Nanocrystalline Inductors for Converter Optimization

Scoltock

Wang

Calderon-Lopez

et al. 2020

IEEE J. Emerg. Sel. Topics Power Electron.

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To capitalize fully on modern component technologies such as nanocrystalline cores and wide-bandgap devices, multi-objective converter design optimization is essential, requiring simple, accurate component models. In this work, a lumped parameter thermal model is presented for nanocrystalline inductors with ceramic heat spreaders. The key challenge is the non-uniform loss distribution in gapped, tape-wound cores, particularly the high loss densities adjacent to the gaps. However, uneven loss distributions are not handled easily by lumped-parameter techniques. It is shown that by treating the ceramic heat spreaders as 'passive' heat sources, a simple thermal model of the inductor can be derived to estimate the hot spot temperature of the core. The model is validated through comparison with 3-D finite element analysis (FEA) and experimental measurements on a 60 kW DC-DC converter. The proposed model offers a comparable level of accuracy to FEA with a fraction of the running time, executing in 99 µs in MATLAB.

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Design optimisation and trade-offs in multi-kW DC-DC converters

Cited by 6 publications

References 15 publications

Power-Dense Bi-Directional DC–DC Converters With High-Performance Inductors

Power-Dense Bi-Directional DC–DC Converters With High-Performance Inductors

Novel Permanent Magnet Synchronous Motor With Integrated Filter Inductor, Using Motor's Inherent Magnetics

Rapid Thermal Analysis of Nanocrystalline Inductors for Converter Optimization

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