Reducing AC-Winding Losses in High-Current High-Power Inductors

Morten Nymand, Udaya K. Madawala, Michael Andreas E. Andersen, Bruce Carsten, Ole S. Seiersen

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    Foil windings are preferable in high-current high-power inductors to realize compact designs and to reduce dc-current losses. At high frequency, however, proximity effect will cause very significant increase in ac resistance in multi-layer windings, and lead to high ac winding losses. This paper presents design, analysis and experimental verification of a two winding technique, which significantly reduces ac winding losses without compromising dc losses. The technique uses an inner auxiliary winding, which is connected in parallel with an outer main winding. The auxiliary winding is optimally designed with low ac resistance and leakage inductance to carry the ac current while the outer winding is designed for the large dc current. Detailed analysis and design of a 350 A, 10 kW inductor with the proposed technique are presented with discussions. Experimental results of a prototype 350 A inductor, used in a 10 kW fuel cell dc-dc converter, are also presented to demonstrate the validity of the proposed technique and its superior performance.
    Original languageEnglish
    Title of host publication35th Annual Conference of the IEEE Industrial Electronics Society
    Publication date2009
    ISBN (Print)978-1-4244-4648-3
    Publication statusPublished - 2009
    Event35th Annual Conference of the IEEE Industrial Electronics Society - Porto, Portugal
    Duration: 3 Nov 20095 Nov 2009
    Conference number: 35


    Conference35th Annual Conference of the IEEE Industrial Electronics Society
    Internet address


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