Analysis of Planar E+I and ER+I Transformers for Low-Voltage High-Current DC/DC Converters with Focus on Winding Losses and Leakage Inductance

Riccardo Pittini, Zhe Zhang, Ziwei Ouyang, Michael A. E. Andersen, Ole Cornelius Thomsen

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Abstract

In this paper an analysis of two planar transformers designed for high-current switching applications is presented. Typical converter application is represented by fuel and electrolyser cell converters. The transformer designs are based on E+I and ER+I planar cores while the analysis focuses on winding resistance and leakage inductances which represent the main concerns related to low-voltage high-current applications. The PCB winding design has a one to one turn ratio with no interleaving between primary and secondary windings. The main goal was to determine if ER planar core could provide a significant advantage in terms of winding losses compared to planar E cores. Results from finite element analysis highlight that low frequency winding resistance is lower for the ER core
since it is dominated by the lower mean turn length however, as the AC-resistance becomes dominating the winding eddy current losses increases more in the ER core than in the E core design.
Calculated and simulated leakage inductances for the analyzed cores do not show relevant differences. A laboratory prototype based on E64 planar core is used as reference. Laboratory
measurements highlight that FEM analysis provides more realistic results when computing the winding AC-resistance.
Original languageEnglish
Title of host publicationProceedings of The International Power Electronics and Motion Control Conference (IPEMC)
PublisherIEEE
Publication date2012
Pages488-493
ISBN (Print)978-1-4577-2087-1
DOIs
Publication statusPublished - 2012
EventThe International Power Electronics and Motion Control Conference - Harbin, China
Duration: 2 Jun 20125 Jun 2012

Conference

ConferenceThe International Power Electronics and Motion Control Conference
CountryChina
CityHarbin
Period02/06/201205/06/2012

Keywords

  • Planar Magnetics
  • Transformer Parasitics
  • DC/DC Switching Converters
  • High-Current
  • Erbium
  • Finite element methods
  • Inductance
  • Resistance
  • Transformer cores
  • Windings

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