Optimal inductor design for a 6.6 kW buck-boost converter

• Main Author: Xu, Dongchen
• Other Authors: Tang Yi
• Format: Thesis-Master by Coursework
• Language: English
• Published: Nanyang Technological University 2024
• Subjects: Engineering; Optimal inductor design; Buck-boost converter; Steinmetz equation
• Online Access: https://hdl.handle.net/10356/176268
• Institution: Nanyang Technological University

Magnetic components (such as transformers and inductors) play crucial roles in switch-mode power supplies, serving tasks like electrical isolation, voltage transformation, and energy buffering. They significantly impact the efficiency, size, and power density of the transformer. As the switching frequency of the transformer continues to increase, the accuracy of high-frequency magnetic component design becomes more prominent in determining transformer performance. Therefore, optimizing the design and rational application of magnetic components is of utmost importance in enhancing the performance of power electronic converters. Achieving precise measurement and calculation of magnetic core losses is a prerequisite and essential condition for all these endeavors. In this paper, we first establish three different models based on magnetic core losses, such as the Steinmetz equation, Rayleigh relation, and parallel resistor model, and validate and analyze losses based on these models. By regressing and integrating complex mathematical derivation models, we obtain visualized loss analysis curves and validate them across different frequency ranges, ultimately deriving appropriate magnetic loss models. Regarding the winding losses, we explore the variation of factors such as the number of windings and permeability with fixed conductor dimensions, obtaining the optimal ratio of windings to magnetic core losses and further refining the loss analysis model. Finally, in the experimental phase, we conducted a comprehensive analysis of magnetic core losses in the inductor section of a high-power Buck-Boost converter environment. We compared and validated the feasibility of the design using data from the manufacturer's magnetic product manual, thereby achieving the research objectives of this paper.