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

Yuliang Cao; Yijie Bai; Vladimir Mitrovic; Boran Fan; Dong Dong; Rolando Burgos; Dushan Boroyevich; Radha Krishna Moorthy; Madhu Sudhan Chinthavali

doi:10.1109/ECCE50734.2022.9947382

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

Yuliang Cao, Yijie Bai, Vladimir Mitrovic, Boran Fan, Dong Dong, Rolando Burgos, Dushan Boroyevich, Radha Krishna Moorthy, Madhu Sudhan Chinthavali

Research output: Chapter in Book/Report/Conference proceeding › Conference contribution › peer-review

11 Scopus citations

Abstract

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.

Original language	English
Title of host publication	2022 IEEE Energy Conversion Congress and Exposition, ECCE 2022
Publisher	Institute of Electrical and Electronics Engineers Inc.
ISBN (Electronic)	9781728193878
DOIs	https://doi.org/10.1109/ECCE50734.2022.9947382
State	Published - 2022
Event	2022 IEEE Energy Conversion Congress and Exposition, ECCE 2022 - Detroit, United States Duration: Oct 9 2022 → Oct 13 2022

Publication series

Name	2022 IEEE Energy Conversion Congress and Exposition, ECCE 2022

Conference

Conference	2022 IEEE Energy Conversion Congress and Exposition, ECCE 2022
Country/Territory	United States
City	Detroit
Period	10/9/22 → 10/13/22

Funding

This project was supported by Oak Ridge National Laboratory (ORNL) and funded by the Department of Energy (DOE) - Office of Electricity’s (OE), Transformer Resilience and Advanced Components (TRAC) program led by the program manager Andre Pereira.

Keywords

Planar magnetics
coupled inductor
electromagnetic interference (EMI)
finite element analysis (FEA)
four-switching buck-boost (FSBB) converter
fringing effect
heavy copper
thermal management
zero common mode (CM) voltage emission
zero voltage switching (ZVS)

Access to Document

10.1109/ECCE50734.2022.9947382

Cite this

Cao, Y., Bai, Y., Mitrovic, V., Fan, B., Dong, D., Burgos, R., Boroyevich, D., Moorthy, R. K., & Chinthavali, M. S. (2022). 3.5 kW/in³ Planar Coupled Inductor Design and Optimization for a 50 kW 3-level Four-Switch Buck-Boost (3L-FSBB) Converter. In 2022 IEEE Energy Conversion Congress and Exposition, ECCE 2022 (2022 IEEE Energy Conversion Congress and Exposition, ECCE 2022). Institute of Electrical and Electronics Engineers Inc.. https://doi.org/10.1109/ECCE50734.2022.9947382

Cao, Yuliang ; Bai, Yijie ; Mitrovic, Vladimir et al. / 3.5 kW/in³ Planar Coupled Inductor Design and Optimization for a 50 kW 3-level Four-Switch Buck-Boost (3L-FSBB) Converter. 2022 IEEE Energy Conversion Congress and Exposition, ECCE 2022. Institute of Electrical and Electronics Engineers Inc., 2022. (2022 IEEE Energy Conversion Congress and Exposition, ECCE 2022).

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

abstract = "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.",

keywords = "Planar magnetics, coupled inductor, electromagnetic interference (EMI), finite element analysis (FEA), four-switching buck-boost (FSBB) converter, fringing effect, heavy copper, thermal management, zero common mode (CM) voltage emission, zero voltage switching (ZVS)",

author = "Yuliang Cao and Yijie Bai and Vladimir Mitrovic and Boran Fan and Dong Dong and Rolando Burgos and Dushan Boroyevich and Moorthy, {Radha Krishna} and Chinthavali, {Madhu Sudhan}",

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Cao, Y, Bai, Y, Mitrovic, V, Fan, B, Dong, D, Burgos, R, Boroyevich, D, Moorthy, RK & Chinthavali, MS 2022, 3.5 kW/in³ Planar Coupled Inductor Design and Optimization for a 50 kW 3-level Four-Switch Buck-Boost (3L-FSBB) Converter. in 2022 IEEE Energy Conversion Congress and Exposition, ECCE 2022. 2022 IEEE Energy Conversion Congress and Exposition, ECCE 2022, Institute of Electrical and Electronics Engineers Inc., 2022 IEEE Energy Conversion Congress and Exposition, ECCE 2022, Detroit, United States, 10/9/22. https://doi.org/10.1109/ECCE50734.2022.9947382

3.5 kW/in³ Planar Coupled Inductor Design and Optimization for a 50 kW 3-level Four-Switch Buck-Boost (3L-FSBB) Converter. / Cao, Yuliang; Bai, Yijie; Mitrovic, Vladimir et al.
2022 IEEE Energy Conversion Congress and Exposition, ECCE 2022. Institute of Electrical and Electronics Engineers Inc., 2022. (2022 IEEE Energy Conversion Congress and Exposition, ECCE 2022).

Research output: Chapter in Book/Report/Conference proceeding › Conference contribution › peer-review

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AU - Mitrovic, Vladimir

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Cao Y, Bai Y, Mitrovic V, Fan B, Dong D, Burgos R et al. 3.5 kW/in³ Planar Coupled Inductor Design and Optimization for a 50 kW 3-level Four-Switch Buck-Boost (3L-FSBB) Converter. In 2022 IEEE Energy Conversion Congress and Exposition, ECCE 2022. Institute of Electrical and Electronics Engineers Inc. 2022. (2022 IEEE Energy Conversion Congress and Exposition, ECCE 2022). doi: 10.1109/ECCE50734.2022.9947382