High Current Planar Magnetics for High Efficiency Bidirectional DC-DC Converters for Fuel Cell Applications

Riccardo Pittini; Zhe Zhang; Michael A. E. Andersen

doi:10.1109/APEC.2014.6803677

High Current Planar Magnetics for High Efficiency Bidirectional DC-DC Converters for Fuel Cell Applications

Riccardo Pittini, Zhe Zhang, Michael A. E. Andersen

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

Abstract

Efficiency is one of the main concerns during the design phase of switch mode power supply. Planar magnetics based on PCB windings have the potential to reduce the magnetic manufacturing cost however, one of their main drawbacks comes from their low filling factor and high stray capacitance. This paper presents an analysis of different planar windings configurations focusing on dc and ac resistances in order to achieve highly efficiency in dc-dc converters. The analysis considers different copper thicknesses form 70 μm up to 1500 μm (extreme copper PCB) taking into account manufacturing complexity and challenges. The analysis is focused on a high current inductor for a dc-dc converter for fuel cell applications and it is based on FEM simulations. Analysis and results are verified on a 6 kW dc-dc isolated full bridge boost converter prototype based on fully planar magnetics achieving a peak efficiency of 97.8%.

Original language	English
Title of host publication	Proceedings of Twenty-Ninth Annual IEEE Applied Power Electronics Conference and Exposition
Publisher	IEEE
Publication date	2014
Pages	2641-2648
ISBN (Print)	978-1-4799-2325-0
DOIs	https://doi.org/10.1109/APEC.2014.6803677
Publication status	Published - 2014
Event	Twenty-Ninth Annual IEEE Applied Power Electronics Conference and Exposition - Fort Worth Convention Center , Fort Worth, TX , United States Duration: 16 Mar 2014 → 20 Mar 2014 http://www.apec-conf.org/

Conference

Conference	Twenty-Ninth Annual IEEE Applied Power Electronics Conference and Exposition
Location	Fort Worth Convention Center
Country	United States
City	Fort Worth, TX
Period	16/03/2014 → 20/03/2014
Internet address	http://www.apec-conf.org/

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Cite this

@inproceedings{e6716a6a2a594e959506333c3853186f,

title = "High Current Planar Magnetics for High Efficiency Bidirectional DC-DC Converters for Fuel Cell Applications",

abstract = "Efficiency is one of the main concerns during the design phase of switch mode power supply. Planar magnetics based on PCB windings have the potential to reduce the magnetic manufacturing cost however, one of their main drawbacks comes from their low filling factor and high stray capacitance. This paper presents an analysis of different planar windings configurations focusing on dc and ac resistances in order to achieve highly efficiency in dc-dc converters. The analysis considers different copper thicknesses form 70 μm up to 1500 μm (extreme copper PCB) taking into account manufacturing complexity and challenges. The analysis is focused on a high current inductor for a dc-dc converter for fuel cell applications and it is based on FEM simulations. Analysis and results are verified on a 6 kW dc-dc isolated full bridge boost converter prototype based on fully planar magnetics achieving a peak efficiency of 97.8%.",

author = "Riccardo Pittini and Zhe Zhang and Andersen, {Michael A. E.}",

year = "2014",

doi = "10.1109/APEC.2014.6803677",

language = "English",

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pages = "2641--2648",

booktitle = "Proceedings of Twenty-Ninth Annual IEEE Applied Power Electronics Conference and Exposition",

publisher = "IEEE",

address = "United States",

note = "Twenty-Ninth Annual IEEE Applied Power Electronics Conference and Exposition , APEC 2014 ; Conference date: 16-03-2014 Through 20-03-2014",

url = "http://www.apec-conf.org/ ",

}

Pittini, R, Zhang, Z & Andersen, MAE 2014, High Current Planar Magnetics for High Efficiency Bidirectional DC-DC Converters for Fuel Cell Applications. in Proceedings of Twenty-Ninth Annual IEEE Applied Power Electronics Conference and Exposition. IEEE, pp. 2641-2648, Twenty-Ninth Annual IEEE Applied Power Electronics Conference and Exposition , Fort Worth, TX , United States, 16/03/2014. https://doi.org/10.1109/APEC.2014.6803677

High Current Planar Magnetics for High Efficiency Bidirectional DC-DC Converters for Fuel Cell Applications. / Pittini, Riccardo; Zhang, Zhe ; Andersen, Michael A. E.

Proceedings of Twenty-Ninth Annual IEEE Applied Power Electronics Conference and Exposition. IEEE, 2014. p. 2641-2648.

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

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T1 - High Current Planar Magnetics for High Efficiency Bidirectional DC-DC Converters for Fuel Cell Applications

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AU - Andersen, Michael A. E.

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N2 - Efficiency is one of the main concerns during the design phase of switch mode power supply. Planar magnetics based on PCB windings have the potential to reduce the magnetic manufacturing cost however, one of their main drawbacks comes from their low filling factor and high stray capacitance. This paper presents an analysis of different planar windings configurations focusing on dc and ac resistances in order to achieve highly efficiency in dc-dc converters. The analysis considers different copper thicknesses form 70 μm up to 1500 μm (extreme copper PCB) taking into account manufacturing complexity and challenges. The analysis is focused on a high current inductor for a dc-dc converter for fuel cell applications and it is based on FEM simulations. Analysis and results are verified on a 6 kW dc-dc isolated full bridge boost converter prototype based on fully planar magnetics achieving a peak efficiency of 97.8%.

AB - Efficiency is one of the main concerns during the design phase of switch mode power supply. Planar magnetics based on PCB windings have the potential to reduce the magnetic manufacturing cost however, one of their main drawbacks comes from their low filling factor and high stray capacitance. This paper presents an analysis of different planar windings configurations focusing on dc and ac resistances in order to achieve highly efficiency in dc-dc converters. The analysis considers different copper thicknesses form 70 μm up to 1500 μm (extreme copper PCB) taking into account manufacturing complexity and challenges. The analysis is focused on a high current inductor for a dc-dc converter for fuel cell applications and it is based on FEM simulations. Analysis and results are verified on a 6 kW dc-dc isolated full bridge boost converter prototype based on fully planar magnetics achieving a peak efficiency of 97.8%.

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