Thermal management of compact nanocrystalline inductors for power dense converters

Wang, Yiren; Calderon-Lopez, Gerardo; Forsyth, A.J.

doi:10.1109/apec.2018.8341398

Cited by 8 publications

(13 citation statements)

References 13 publications

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“…A multi-physics approach with coupled three-dimension (3D) electromagnetic (EM) and thermal FE simulations [23] in Opera-3D was used. First, the gap loss is obtained with the harmonic EM FE solver, then the overall core losses are transferred to the static thermal solver, which contains the models of the windings, potting and aluminum can.…”

Section: A Derivation Of Practical Design From Optimization Resultsmentioning

confidence: 99%

“…The EM simulations considered the four sub-cores, and the thermal simulations assumed a constant temperature boundary condition at the base of the aluminum can. Full details of the FE method, along with the thermal conductivities of the materials are provided in [23].…”

Section: A Derivation Of Practical Design From Optimization Resultsmentioning

confidence: 99%

“…Each inductor comprised four nanocrystalline sub-cores rated to 180 C [25], with overall dimensions equivalent to a Finemet F3CC0025 core [19]. Ceramic tiles were used as the gap spacers [23], and the coils have two 125-µm copper foils. The potting compound is rated at 3.2 W/mK [26].…”

Section: B Construction Detailsmentioning

confidence: 99%

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Power-Dense Bi-Directional DC–DC Converters With High-Performance Inductors

Calderon-Lopez

Scoltock

Wang

et al. 2019

IEEE Trans. Veh. Technol.

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An investigation is described into the optimization of multi-phase, high power, bi-directional DC-DC interleaved converters suitable for Electric Vehicle (EV) applications. Two dual-interleaved topologies were considered initially for the optimization, the main difference being the magnetic devices: either discrete inductors (DI) or an Interphase Transformer (IPT). The comparison used a comprehensive multi-objective design optimization procedure for an 80 kW case study. High performance inductors comprising a split-core structure and dual-foil windings to reduce losses, and a 180 C core, enabled the DI to be competitive with IPT in terms of power density and efficiency. The optimized designs are validated experimentally with an 80 kW bi-directional SiC DC-DC converter, achieving a power density of 31.4 kW/L and specific power of 15.7 kW/kg. The study is then extended to 100-kW three and four-phase interleaved topologies.

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Section: A Derivation Of Practical Design From Optimization Resultsmentioning

confidence: 99%

Section: A Derivation Of Practical Design From Optimization Resultsmentioning

confidence: 99%

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Power-Dense Bi-Directional DC–DC Converters With High-Performance Inductors

Calderon-Lopez

Scoltock

Wang

et al. 2019

IEEE Trans. Veh. Technol.

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“…These components together with ferromagnetic materials allow improving the performance of PECs Nowadays it is estimated that magnetic components of a PEC operating at high-frequency can be more than 50 % of the total system weight [17]- [19]. For this reason, the design of magnetic components requires a high accuracy fabrication.…”

Section: Introductionmentioning

confidence: 99%

Advanced Ferromagnetic Materials in Power Electronic Converters: A State of the Art

et al. 2020

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Currently, the design of power electronic converters (PECs) is in a stage which looks increasing its efficiency and reducing its dimensions from basic topologies through precise analysis of losses in each device that conforms. Although there have been important advances to improve the active components of PECs, passive components, particularly inductors, have changed very little since several decades ago, and those begin a limiting factor, when a high efficiency at very high power and switching frequency, are required. It is for the foregoing that this paper reviews new ferromagnetic materials to construct inductors and achieve a substantial increasing in efficiency through magnetic permeability and hysteresis improvements. Therefore, the main objective of this work is to position the reader in the state of the art of advanced ferromagnetic materials used in PECs. Details about how they are constructed and qualitative comparison of their dynamic behavior are provided. Also, estimation methods of energy losses, applications for different types of material, and its influence on the performance of some basic PECs are presented. INDEX TERMS Amorphous magnetic materials, magnetic materials, power conversion, soft magnetic materials.

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“…However, due to the high electrical conductivities of the amorphous metal ribbon that forms the cores, intense heating can occur around air gaps in the magnetic circuit due to the perpendicular component of the fringe-field [16,17]. One way to reduce the hot spots in the core is through the use of high-thermal-conductivity heat spreaders placed around the gap [18], for example using aluminum nitride. Further, a number of methods have been proposed to reduce gap losses including the use of multiple smaller gaps around the magnetic circuit [19], cutting slits in the cores near the air gap [20], or splitting the core into several sub-cores placed side-by-side [21].…”

Section: Introductionmentioning

confidence: 99%

Rapid Thermal Analysis of Nanocrystalline Inductors for Converter Optimization

Scoltock

Wang

Calderon-Lopez

et al. 2020

IEEE J. Emerg. Sel. Topics Power Electron.

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To capitalize fully on modern component technologies such as nanocrystalline cores and wide-bandgap devices, multi-objective converter design optimization is essential, requiring simple, accurate component models. In this work, a lumped parameter thermal model is presented for nanocrystalline inductors with ceramic heat spreaders. The key challenge is the non-uniform loss distribution in gapped, tape-wound cores, particularly the high loss densities adjacent to the gaps. However, uneven loss distributions are not handled easily by lumped-parameter techniques. It is shown that by treating the ceramic heat spreaders as 'passive' heat sources, a simple thermal model of the inductor can be derived to estimate the hot spot temperature of the core. The model is validated through comparison with 3-D finite element analysis (FEA) and experimental measurements on a 60 kW DC-DC converter. The proposed model offers a comparable level of accuracy to FEA with a fraction of the running time, executing in 99 µs in MATLAB.

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Thermal management of compact nanocrystalline inductors for power dense converters

Cited by 8 publications

References 13 publications

Power-Dense Bi-Directional DC–DC Converters With High-Performance Inductors

Power-Dense Bi-Directional DC–DC Converters With High-Performance Inductors

Advanced Ferromagnetic Materials in Power Electronic Converters: A State of the Art

Rapid Thermal Analysis of Nanocrystalline Inductors for Converter Optimization

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