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DC-DC converters with wide-bandgap semiconductors facilitate the operation at higher switching frequencies. Thus, inductors can be reduced in size which is beneficial in regard to power density and weight of the converter. As a drawback, high frequency inductors suffer from considerably large winding losses caused by skin and proximity effects. Litz wire is a possible solution but it results in a...
This paper focuses on the loss analysis and optimized design of DC-DC converter for battery module. By using the data measured from the experiment study of inductor loss and component datasheets to derive the inductor, MOSFET, and capacitor loss equations of bidirectional buck converter, boost converter, and buck-boost converter through numerical analysis. In addition, the charging and discharging...
A three-dimensional mathematical modeling and an analysis of the magnetic and temperature fields distribution in a lined inductor of melting-holding furnace for copper melting have been made. The analysis has been made based on the following objects properties: a complex geometry of the system; a non-linear conductivity dependence on the copper temperature; ferromagnetic properties of the iron magnetic...
Wound components typically represent approximately 50 % of the total mass of a power converter, consequently minimising the mass and volume of transformers and filter inductors is an important challenge in the design of compact power dense converters in transport and other demanding applications. The research described in this paper contributes to a body of work investigating design tools and new...
With increased demand in electric drives applications for higher power density, higher efficiency and higher temperature operation, integrated motor drives are gaining greater interest in automotive, aerospace and other specialist applications. Integrated drives not only physically integrate the various components of the drive (power electronic devices, filter components etc.) they must also integrate...
Given the recent interest in power delivery design for the Internet of Things (IoT), current work aims to design a packaged power delivery solution for IoT. The power inductor takes up a large amount of the area in such an implementation. Planar power inductors are preferred for fabrication simplicity and cost. However, air core inductors do not have sufficient area efficiency for IoT solutions, necessitating...
Discrete sub-system due to passive elements in motor drive require functional and structural integration to make efficient and power dense overall system. Such power dense system is the prerequisite in aerospace and marine applications. This paper presents the design optimization of integrated rotor-less inductors for high speed AC drive applications. Different slot-pole combinations are considered...
Two designs of integrated magnetic planar transformer called Face to Face transformer are studied: The first one consists in depositing the copper windings on the magnetic material, the second consists in micromachining the magnetic layer before depositing the conductive layer in order to bury copper windings inside the magnetic material.
With the increasing demand of low-profile, high-power density for power electronics system, the planar magnetics (inductors and transformers) begin to be adopted in many fields. The copper tracks on printed circuit board (PCB) are mostly adopted as the windings of the planar magnetics which cannot be changed flexibly once the PCB is produced. So the design method of planar magnetics is an important...
In this work we describe a simple and effective set of techniques to decrease the parasitic effects that undermine the performance of EMI filters at high frequencies. These techniques involve the use of bands of copper tape conveniently placed around the components of the filter. These techniques are practically cost-free and can be easily and quickly implemented on-site during pre-compliance tests...
The effect of core and copper losses on a novel magnetic compression based stepped impedance transmission line pulse generator circuit is presented. Design equations are derived and presented which take into account the current leakage into neighboring cells, losses due to magnetizing inductance currents, losses due to saturable cores and copper losses in the saturated inductance windings. It is shown...
This paper presents the design of a low mass RF power inverter at moderate to high power levels (e.g. tens of watts and above) for weight critical applications such as cubesat plasma thrusters. Our approach for mass reduction includes resonant switching operation at tens of MHz, and the 3D printing of light-weight scaffolds that form air core inductors after plating with a thin layer of copper. Specifically,...
This paper introduces an innovative concept of electrical-thermal co-design for high-Q 3D inductors using through-package-via (TPV)-based copper networks in ultra-thin power amplifier-integrated glass modules. The copper networks are designed to provide high quality factor inductors, and also simultaneously enable heat transfer in ultra-miniaturized glass packages. Such TPV-based 3D inductors achieved...
For the further miniaturization of integrated circuits, the integration of passive components on the chip is one approach. In DC-DC converter applications, the integration of the inductor with high inductivity is one problem. This paper addresses this problem by proposing a new technique for fabricating a multilayer spiral coil that is also useful as part of electromagnetic MEMS (Micro-Electro-Mechanical...
Integrated inductor with magnetic core is one of the three significant passive components for PCB (Printed Circuit Board) assembly. In this paper, a novel structure of integrated inductor with Ni-P (low P content) magnetic core deposited on the as-patterned conductive copper lines was fabricated by directly electroless-plating method. Two types of PCB integrated inductor with patterns of rectangle...
Galvanically isolated dc-dc converters require a certain series inductance in the ac link. Since it complicates the design process, the stray inductance of the transformer might not be designed sufficiently. This paper designs dedicated inductors to be operated in the medium-frequency ac link of a high-power dc-dc converter rated for 5 MW to increase the effective stray inductance. Different core...
Present study analyzed the efficiency characteristics of LLC converters having current doubler rectification circuits. A current doubler rectification circuit has a coupled inductor as rectification circuit on the secondary side output terminal of the converter. A current doubler rectification circuit generally requires inductors on the secondary side however, the characteristic of an LLC converter...
This paper studies the inductor design for three-wire and four-wire power factor correction converter (PFC). Designing the efficient inductor for this converter (regardless of connecting the midpoint to the ground) requires a comprehensive knowledge of the inductor current and voltage behavior. This paper investigates how changing three-wire PFC to four-wire counterpart influences the inductor design...
This article concerns the development, the realization and the characterization of integrated inductors using magnetic layers for use in power electronics. Measurements carried out with a Vector Network Analyzer up to 1 GHz are presented. Results show that the use of two magnetic layers allows multiplying the air core inductance by 15 for 500 µm magnetic thickness layers.
Realizing an integrated Power Supply in Package solution using a 2.5D or 3D integration technology requires significant advancement in manufacturing processes of magnetic components such as inductors, transformer. Development of these integrated structures involves fabrication of high aspect ratio integrated windings and 3D core topology. These process improvements are required to reduce the losses...
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