Improved single‐layer powder core inductor design procedure for DC‐DC converters

Abstract

AbstractOne of the early design decisions for DC‐DC converters is the choice of an appropriate magnetic core material. Powder cores in particular are suitable due to their saturation flux density of up to 1.5 T. However, high DC currents constitutes a significant problem since the winding cross‐section rises with the current, which consequently increases AC losses due to skin effects. Another challenge is the reduction of winding layers to decrease proximity losses. This paper presents an improved single‐layer winding design procedure for DC‐DC converter powder cores. The procedure determines the optimum number of parallel cores and stacks. This way, the procedure enables a predefined maximum wire cross‐section for copper loss optimisation and single‐layer winding. The introduced approach defines the optimum switching frequency as a trade‐off between core loss and core volume. Finally, experimental tests with two setups validate 27 kW DC‐DC converters and hence the design procedure using Si‐IGBTs and SiC‐MOSFETs. The results demonstrate that SiC‐MOSFETs reduce core volume by a factor of 3 compared to Si‐IGBTs. Further, the SiC setup reaches high efficiencies of up to 98.53% compared to 98.17% for the Si‐based converter.