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

doi:10.1109/IPEMC.2012.6258778

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

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

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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 language	English
Title of host publication	Proceedings of The International Power Electronics and Motion Control Conference (IPEMC)
Publisher	IEEE
Publication date	2012
Pages	488-493
ISBN (Print)	978-1-4577-2087-1
DOIs	https://doi.org/10.1109/IPEMC.2012.6258778
Publication status	Published - 2012
Event	The International Power Electronics and Motion Control Conference - Harbin, China Duration: 2 Jun 2012 → 5 Jun 2012

Conference

Conference	The International Power Electronics and Motion Control Conference
Country/Territory	China
City	Harbin
Period	02/06/2012 → 05/06/2012

Keywords

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

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Pittini, R., Zhang, Z., Ouyang, Z., Andersen, M. A. E., & Thomsen, O. C. (2012). 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. In Proceedings of The International Power Electronics and Motion Control Conference (IPEMC) (pp. 488-493). IEEE. https://doi.org/10.1109/IPEMC.2012.6258778

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title = "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",

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 coresince 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. Laboratorymeasurements highlight that FEM analysis provides more realistic results when computing the winding AC-resistance.",

keywords = "Planar Magnetics, Transformer Parasitics, DC/DC Switching Converters, High-Current, Erbium, Finite element methods, Inductance, Resistance, Transformer cores, Windings",

author = "Riccardo Pittini and Zhe Zhang and Ziwei Ouyang and Andersen, {Michael A. E.} and Thomsen, {Ole Cornelius}",

year = "2012",

doi = "10.1109/IPEMC.2012.6258778",

language = "English",

isbn = "978-1-4577-2087-1",

pages = "488--493",

booktitle = "Proceedings of The International Power Electronics and Motion Control Conference (IPEMC)",

publisher = "IEEE",

address = "United States",

note = "The International Power Electronics and Motion Control Conference , IPEMC 2012-ECCE Asia ; Conference date: 02-06-2012 Through 05-06-2012",

}

Pittini, R, Zhang, Z, Ouyang, Z , Andersen, MAE & Thomsen, OC 2012, 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. in Proceedings of The International Power Electronics and Motion Control Conference (IPEMC). IEEE, pp. 488-493, The International Power Electronics and Motion Control Conference , Harbin, China, 02/06/2012. https://doi.org/10.1109/IPEMC.2012.6258778

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. / Pittini, Riccardo; Zhang, Zhe; Ouyang, Ziwei et al.
Proceedings of The International Power Electronics and Motion Control Conference (IPEMC). IEEE, 2012. p. 488-493.

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

TY - GEN

T1 - 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

AU - Pittini, Riccardo

AU - Zhang, Zhe

AU - Ouyang, Ziwei

AU - Andersen, Michael A. E.

AU - Thomsen, Ole Cornelius

PY - 2012

Y1 - 2012

N2 - 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 coresince 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. Laboratorymeasurements highlight that FEM analysis provides more realistic results when computing the winding AC-resistance.

AB - 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 coresince 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. Laboratorymeasurements highlight that FEM analysis provides more realistic results when computing the winding AC-resistance.

KW - Planar Magnetics

KW - Transformer Parasitics

KW - DC/DC Switching Converters

KW - High-Current

KW - Erbium

KW - Finite element methods

KW - Inductance

KW - Resistance

KW - Transformer cores

KW - Windings

U2 - 10.1109/IPEMC.2012.6258778

DO - 10.1109/IPEMC.2012.6258778

M3 - Article in proceedings

SN - 978-1-4577-2087-1

SP - 488

EP - 493

BT - Proceedings of The International Power Electronics and Motion Control Conference (IPEMC)

PB - IEEE

T2 - The International Power Electronics and Motion Control Conference

Y2 - 2 June 2012 through 5 June 2012

ER -

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

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