Design of a 2.5kW PFC boost full-SiC converter based on close-coupled inductors

Applications such as Hybrid Electric Vehicles (HEV), vertical transportation and railway traction require very high power converters with the volume limitations intrinsic to onboard applications. High power density can be achieved by using higher switching frequencies, Silicon Carbide (SiC) power switches and coupled inductors topologies. In this paper, close-coupled inductors topologies are modeled, simulated and designed for a 2.5kW interleaved PFC boost all-SiC converter. Design and simulation results are validated through experimental measurements on a converter prototype. Both the traditional interleaved converter and the close-coupled inductors topology are compared. Inductor effective volume is reduced by 53.54% and 97.385% efficiency is achieved.

[1]  Xu Yang,et al.  Design of Ultrathin LTCC Coupled Inductors for Compact DC/DC Converters , 2011, IEEE Transactions on Power Electronics.

[2]  T. O'Donnell,et al.  Microfabricated coupled inductors for DC-DC converters for microprocessor power delivery , 2004, 2004 IEEE 35th Annual Power Electronics Specialists Conference (IEEE Cat. No.04CH37551).

[3]  S. Hashino,et al.  High power density DC/DC converter using the close-coupled inductors , 2009, 2009 IEEE Energy Conversion Congress and Exposition.

[4]  N. Oswald,et al.  An Experimental Investigation of the Tradeoff between Switching Losses and EMI Generation With Hard-Switched All-Si, Si-SiC, and All-SiC Device Combinations , 2014, IEEE Transactions on Power Electronics.

[5]  Guangyong Zhu,et al.  Modeling and Analysis of Coupled Inductors in Power Converters , 2009, 2009 Twenty-Fourth Annual IEEE Applied Power Electronics Conference and Exposition.

[6]  Amit Patra,et al.  Design Principles of a Symmetrically Coupled Inductor Structure for Multiphase Synchronous Buck Converters , 2011, IEEE Transactions on Industrial Electronics.

[7]  Fred C. Lee,et al.  A new coupled inductors design in 2-phase interleaving VRM , 2009, 2009 IEEE 6th International Power Electronics and Motion Control Conference.

[8]  B. Cougo,et al.  Comparative Evaluation of Individual and Coupled Inductor Arrangements for Input Filters of PV Inverter Systems , 2012, 2012 7th International Conference on Integrated Power Electronics Systems (CIPS).

[9]  D. O. Boillat,et al.  Modeling and experimental analysis of a Coupling Inductor employed in a high performance AC power source , 2012, 2012 International Conference on Renewable Energy Research and Applications (ICRERA).

[10]  Enrico Santi Magnetics and control in power electronics : I. Modeling of coupled inductors. II. One-cycle control of switching converters , 1994 .

[11]  J. Pforr,et al.  Turn-on behavior of automotive multi-phase converters with coupled inductors , 2012, 2012 15th International Power Electronics and Motion Control Conference (EPE/PEMC).

[12]  Yim-Shu Lee,et al.  A two-channel interleaved boost converter with reduced core loss and copper loss , 2004, 2004 IEEE 35th Annual Power Electronics Specialists Conference (IEEE Cat. No.04CH37551).

[13]  T. Shimizu,et al.  High power DC/DC converter using extreme close-coupled inductors aimed for electric vehicles , 2010, The 2010 International Power Electronics Conference - ECCE ASIA -.