Advances in High Frequency
Inductor Design for
Power Converter
Bima Nugraha Sanusi
Ph.D.Thesis Technical University of
Denmark.
Abstract
The Power Sources Manufacturers Association roadmap identifies high-efficiency and
high-power-density end-use of electricity as one of the key challenges to increase the
economic growth rate with a minimal environmental impact. The challenge in realizing
smaller, faster, and in turn greener power supplies is the integration of magnetic
materials that can operate efficiently at high frequency. The most successful work will
involve magnetic material development, optimization of magnetic component designs,
and consideration of fabrication constraints.
This project primarily aims for a high-efficiency and high-power-density power management
(DC/DC converter) from the USB-C port to the battery within the next generation
of fast-charging smartphones or other portable electronic devices. This thesis
hypothesizes that employing superparamagnetic nanoparticles material, which has high
permeability and negligible hysteresis loss, in high-frequency inductor design can enable
high-efficiency and high-power-density converter. The focus of this thesis will be
on the magnetic material characterization and the inductor design.
The first step is to establish a baseline prototype with state-of-the-art magnetic
material. Multi-phase Zero Voltage Switching (ZVS) Buck converter is the selected
topology to achieve high power density. A novel utilization of 4-leg magnetic core is
proposed as the integrated inductor. From the constructed inductor model and semiconductor
losses calculation, the design trade-off is analyzed. The optimal switching
frequency is found to be around 2 MHz in this case, which is when the core material
performance factor peaks. As proof of concept, a highly compact prototype, featuring
stacked PCB solution is built. The input voltage ranges from 6 V to 12 V and the converter
can deliver up to 10 A at 4 V output. The converter reaches a nominal efficiency
of 88% and has a power density of 301 W/in3.
The second step is to build a platform for magnetic core characterization, in particular
the core loss. Mutual inductance compensation method is employed in the
measurement circuit to reduce sensitivity to phase errors. An addition to the circuit
is proposed in this work to make easier DC bias generation. This platform is used to
study the core losses behavior at high frequency with superimposed DC bias in ferrite.
The tested MnZn ferrite has a nominal relative permeability of 1500 and 800, which
was tested at frequency from 500 kHz to 3 MHz. The measurement results are explained
thoroughly with three controlling parameters: excitation frequency, AC flux
density amplitude, and DC bias. Furthermore, an improved Steinmetz Premagnetization
Graph and Artificial Neural Network are used to create core loss prediction model.
The measurement data and built model can be accessed online for use by another
magnetics designer.
The third step is to analyze the switching transition in multi-phase half-bridge
circuit with coupled inductors. It was found that the coupled inductors can achieve or
maintain ZVS in the cases where non-coupled inductors cannot. Moreover, the coupled
inductors can reduce the required deadtime to achieve ZVS. This benefit comes from
the increased amplitude and frequency of resonant voltage in the presence of coupled
inductors. The impact is quantified, analyzed, and verified in this thesis.
ORIGINAL LINK: https://orbit.dtu.dk/en/publications/advances-in-high-frequency-inductor-design-for-power-converter/