3.5 kW/in3 Planar Coupled Inductor Design and Optimization for a 50 kW 3-level Four-Switch Buck-Boost (3L-FSBB) Converter

Conference · Tue Nov 01 00:00:00 EDT 2022

DOI:https://doi.org/10.1109/ECCE50734.2022.9947382· OSTI ID:1905398

Cao, Yuliang ^[1]; Bai, Yijie ^[1]; Mitrovic, Vladimir ^[1]; Fan, Boran ^[1]; Dong, Dong ^[1]; Burgos, Rolando ^[1]; Boroyevich, Dushan ^[1]; Krishna Moorthy, Radha  ^[2]; Chinthavali, Madhu Sudhan  ^[2]

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1. Virginia Tech, Blacksburg, VA
2. ORNL

Planar magnetics design has been widely used in power electronics field because of the low profile, ease of manufacturability, and high power density. This paper first proposes a 3-level four-switch buck-boost (3L-FSBB) converter for the dc-dc applications where the zero common-mode (CM) voltage emissions, step-up and step-down are all required. With the consideration of power density, efficiency, and cost, a 15oz heavy copper coupled inductor for 3-level FSBB converter was designed and optimized with the low-cost commercial core and planar windings. According to the soft-switching quadrangle modulation for 3-L FSBB, the turns number and stacked core number are optimized first. And then, a two-board design is proposed to reduce the fringing effect and improve the thermal performance. Finally, a 75 kVA two-stage ac-dc-dc converter including a 3-level FSBB converter was built to verify the electrical design.

• Research Organization: Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)
• Sponsoring Organization: USDOE Office of Electricity (OE)
• DOE Contract Number: AC05-00OR22725
• OSTI ID: 1905398
• Resource Relation: Conference: 2022 IEEE Energy Conversion Congress and Exposition (ECCE) - Detroit, Michigan, United States of America - 10/9/2022 12:00:00 PM-10/13/2022 12:00:00 PM
• Country of Publication: United States
• Language: English