Optimal inductor design for 3-phase voltage-source PWM converters considering different magnetic materials and a wide switching frequency range

Burkart, Ralph M.; Uemura, Hirofumi; Kolar, Johann W.

doi:10.1109/ipec.2014.6869693

Cited by 40 publications

(8 citation statements)

References 20 publications

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“…• Inductor volume: For parallel connected converter cells the total amount of stored energy in the associated inductors decreases with increasing number of cells until the DC-value of the conducted current in each inductor becomes negligble compared to the current ripple. Since the stored energy in inductors is related to their volume [9], the total inductor volume in parallel-interleaved systems also decreases. • Heatsink volume: In multi-cell converters the transferred power and thereby also the losses are equally distributed among the converter cells if operated with a common duty-cycle.…”

Section: Further Scaling Lawsmentioning

confidence: 99%

Hyper-efficient (98%) and super-compact (3.3kW/dm<sup>3</sup>) isolated AC/DC telecom power supply module based on multi-cell converter approach

Kasper

Bortis

Kolar

et al. 2014

2014 IEEE Energy Conversion Congress and Exposition (ECCE)

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In this paper, a multi-cell converter approach for a telecom rectifier module breaking through the efficiency and power density barriers of traditional single-cell converter systems is shown. The potential of the multi-cell approach for high efficiency is derived from fundamental scaling laws of the system performances, such as the losses generated by the semiconductors and the harmonic spectrum, in dependence of the number of converter cells. Furthermore, a comprehensive optimization of the entire system with respect to efficiency and volume has been performed and the applied component loss models are described in detail. The achievable performance of the system is compared to a leading edge state-of-the-art single-cell converter system which currently sets the benchmark in terms of efficiency and power-density. In addition, the degrees of freedom of multi-cell converter systems in terms of converter operation are outlined and optimum control schemes are derived. I. INTRODUCTIONToday's single-phase telecom power supply modules usually comprise a PFC rectifier stage and an isolated DC-DC converter output stage, typically generating a nominal output voltage of 48 V. The rectifier stage in conventional power electronic systems is a boost-type PFC rectifier which consists of a full-bridge diode rectifier in connection with a boost converter. Since the forward voltage drops of the diodes in the rectifier account for high conduction losses, alternative topologies have gained significant interest over the past years [1], [2]. E.g. in [3] a triple-parallel-interleaved TCM PFC rectifier system is described in combination with a double-parallel-interleaved phase-shift full-bridge isolated DC-DC converter for telecom applications (rated power P out = 3.3 kW, output voltage V out = 48 V) featuring a power density of ρ = 3.3 kW/dm 3 and an efficiency of η = 97 % at half of the rated power. As shown in [4], this concept currently presents the leading edge technology for telecom power supplies and therefore serves as a benchmark system in this paper. A new approach towards a hyper-efficient and super-compact telecom rectifier design beyond the barriers of traditional converter concepts is presented in this paper. The approach is based on a multi-cell converter concept that leverages the advantages obtained by employing multiple series-parallel connected converter cells instead of a single converter, such as lower conduction and switching losses and reduction of harmonics by interleaving [5]. The performance targets that can be achieved with this approach are an output power of P out = 3.3 kW with a conversion efficiency of 98% at part

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Section: Further Scaling Lawsmentioning

confidence: 99%

Hyper-efficient (98%) and super-compact (3.3kW/dm<sup>3</sup>) isolated AC/DC telecom power supply module based on multi-cell converter approach

Kasper

Bortis

Kolar

et al. 2014

2014 IEEE Energy Conversion Congress and Exposition (ECCE)

Self Cite

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“…Regarding the power loss, the loss characterisation of inductors in general, and their core loss in particular, has been a hot research topic. Accurate estimation of inductor core loss is crucial for the thermal design and optimisation of power converters [2]- [4] in early design stage. It is especially important when considers the high-frequency operation and associated highfrequency core loss with the use of wide-bandgap switching devices.…”

Section: Introductionmentioning

confidence: 99%

A Practical Approach for Core Loss Estimation of a High-Current Gapped Inductor in PWM Converters With a User-Friendly Loss Map

Wang

Dagan

Yuan

et al. 2019

IEEE Trans. Power Electron.

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Core loss estimation of filter inductors is critical for modelling and optimising high-frequency, highefficiency and high-density Pulse Width Modulation (PWM) power electronics converters. However, data provided by inductor core manufacturers is insufficient for core loss estimation in PWM converters, particularly in the case of customized gapped inductors. This paper presents a whole process of characterising and estimating the core loss of a customised high-current gapped inductor for PWM converters. To excite the inductor for the B-H loop measurement, a test circuit formed by a half-bridge structure is proposed, which has the ability to compensate the asymmetric rectangular voltage on the inductor caused by the device voltage drops. To overcome the other challenges raised by high excitation current, a discontinuous test procedure, Triple Pulse Test (TPT), is applied to reduce the requirements of the high-current test setup (thermal stress, current-time stress for current probes, capacity of dc sources, etc.). For practical purposes, a user-friendly loss map approach is proposed involving only time-domain and electrical variables to replace magnetic variables to enable straightforward loss mapping process and core loss calculations. Presented experimental results show consistency between the estimated inductor loss and measured values. Overall, the proposed testing approach can be easily implemented on the user's side to develop a loss map of a given inductor. The established core loss map enables the users to accurately and rapidly estimate the core loss of a tested inductor for given PWM waveforms.

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“…The celebrated general Steinmetz equation for core loss given in Equation (11) and the copper loss given in Equation (15) can be used to evaluate the temperature rise in the inductor.…”

Section: Core Materials Selectionmentioning

confidence: 99%

“…Compact and efficient magnetic components design in the power inverter results in minimization of its total size and weight; thus, magnetic material plays an important role in the grid-connected high power density inverter [6,7]. Winding technology [8][9][10], switching frequency [11], and core selection [12] are three important issues in the size reduction of magnetic components in the LCL filter. Furthermore, current harmonic distortion of the grid-connected power inverter must be considered because of the power quality requirement in the power grid.…”

Section: Introductionmentioning

confidence: 99%

LCL Filter Design with EMI Noise Consideration for Grid-Connected Inverter

Liu

Lai

2018

Energies

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The grid-injected current total harmonics distortion (THD) and electromagnetic interference (EMI) noise must be considered in a transformer-less grid-connected inverter for a more electric aircraft (MEA) system. This paper develops a procedure for the design of the magnetic components of the LCL filter used in harmonic control and EMI reduction of the silicon carbide (SiC) grid-connected inverter in the MEA. The LCL filter is designed with effective harmonic attenuation and a compact size. To meet the space constraint requirement, specific design attention is focused on a customized amorphous cored inductor, with a comprehensive study of the relationships of inductor winding with respect to EMI noise. Reduced THD and EMI are verified through experiments performed on a 30 kW, 230 V/400 Hz three-phase grid-connected inverter prototype with the LCL filter.

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Optimal inductor design for 3-phase voltage-source PWM converters considering different magnetic materials and a wide switching frequency range

Cited by 40 publications

References 20 publications

Hyper-efficient (98%) and super-compact (3.3kW/dm<sup>3</sup>) isolated AC/DC telecom power supply module based on multi-cell converter approach

Hyper-efficient (98%) and super-compact (3.3kW/dm<sup>3</sup>) isolated AC/DC telecom power supply module based on multi-cell converter approach

A Practical Approach for Core Loss Estimation of a High-Current Gapped Inductor in PWM Converters With a User-Friendly Loss Map

LCL Filter Design with EMI Noise Consideration for Grid-Connected Inverter

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