A High-Power-Density Active-Clamp Converter with Integrated Planar Transformer
Abstract
:1. Introduction
2. Features of the Proposed Converter
2.1. Descriptions of the Proposed Converter
- (1)
- The power density of the proposed converter is similar to that of high-frequency converters, which have over 500 kHz operating frequency.
- (2)
- Input/output voltage range characteristics of the proposed converter are similar to conventional PWM isolated converters with an output inductor.
- (3)
- The high price competitiveness and low cost can be achieved by eliminating the output inductor, reducing the winding configuration cost, and simplifying the structure of the rectifier structure.
2.2. Operational Principles
- (1)
- All parasitic components are ignored except for parasitic components in Figure 4;
- (2)
- A clamp capacitor (CC) is large enough to be considered as a constant voltage source (VCc);
- (3)
- The output voltage (VO) is constant since the output is connected to the LV battery;
- (4)
- The transformer turns ratio (n) of the forward and flyback transformers (Tfor and Tfly) is N/1, where N is a number of the primary winding.
3. Analysis of Proposed Converter
3.1. DC Conversion Ratio
3.2. Design Consideration of Transformer
3.3. Loss Analysis of Proposed Converter
- (1)
- The magnetizing inductances of the transformer are large enough, so the magnetizing current ripples of the transformer are small enough to be ignorable.
- (2)
- The leakage inductance of the transformer is small enough to be negligible, and because of that, the commutation periods can be ignorable.
4. Experimental Results
5. Conclusions
Author Contributions
Funding
Acknowledgments
Conflicts of Interest
References
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Parameter | Conventional Integrated Transformer | Proposed Integrated Planar Transformer |
---|---|---|
V/VO, PO | 270 V/13.9 V, 1.8 kW | |
Switching frequency | 150 kHz | 200 kHz |
Core | PQ6640 custom | UI3323 × 2EA |
Flux variation (ΔBfor/ΔBfly) | 0.16 T | 0.157 T/0.143 T |
Core volume | 71,396 mm4 | 42,268 mm4 |
Primary windings area/current density (A/cm2) | 0.1Φ 250 strands/559 A/cm2 | 0.105 mm × 2.6 mm/4046 A/cm2 |
Resistance of primary winding | 0.014 Ω | 0.1 Ω |
Secondary winding area/current density (A/cm2) | 2 mm × 10 mm/456 A/cm2 | 0.105 mm × 11.3 mm × 2/3737 A/cm2 |
Resistance of primary winding | 0.1 mΩ | 0.6 mΩ |
Magnetizing inductance (Lm,for/Lm,fly) | 50 μH/40 μH | 30 μH/30 μH |
Leakage inductance | 5 μH | 2 μH |
Core loss | 4.28 W | 2.66 W |
Primary winding loss | 1.34 W | 13.76 W |
Secondary winding loss | 3.27 W | 13.33 W |
Total loss of transformer | 8.89 W | 29.75 W |
Parameter | PSFB | FBACFF | Proposed ACFF |
---|---|---|---|
RMS currents on switches (A) | , Q2, Q3 : – | , QA : – | |
Voltage stress on switches (V) | |||
Voltage stresses on diodes (V) |
Parameter | PSFB | FBACFF | Proposed ACFF |
---|---|---|---|
Primary switch Part number/Price ($) | Q1–Q4: IPW65R115/4.636 | Q1, Q4: IPW65R115/4.636, Q2, Q3: IPW65R190/2.69 | QM: C3M0120090/7.47 QA: C3M0280090/4.03 |
Total price of primary switches ($) | 18.544 | 14.652 | 11.5 |
Transformer/inductor | EER4730 /EER6025 | EE6630 | UI3323 × 2 EA |
Price of magnetics($) | 20 | 12 | 5 |
Total Price ($) | 38.544 | 26.625 | 16.5 |
Components | Conventional FBACFF with Integrated Transformer | Proposed ACF with Integrated Planar Transformer |
---|---|---|
Primary switch | Q1, Q4: IPW60R080 Q2, Q3: IPW60R190 | QM: C3M0120090 QA: C3M0280090 |
Secondary diode | M80QZ12N, 2 EA | VS-63CPQ100, 4 EA |
Clamp cap | Film: 630 V, 1 uF | MLCC: 150 nF, 4 EA |
Transformer | Core: PQ6640, Lm,for = 50 μH, Lm,fly = 40 μH Llkg = 5 μH, Np:Ns = 8:1 | Core: UI3323, 2 EA, Lm,for = Lm,fly = 30 μH, Llkg = 2 μH, Np:Ns = 8:1 |
Output cap | MLCC: 22 μF × 6 EA | MLCC: 10 μF, 8 EA |
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Lee, D.-W.; Lim, J.-H.; Lee, D.-I.; Youn, H.-S. A High-Power-Density Active-Clamp Converter with Integrated Planar Transformer. Energies 2022, 15, 5609. https://doi.org/10.3390/en15155609
Lee D-W, Lim J-H, Lee D-I, Youn H-S. A High-Power-Density Active-Clamp Converter with Integrated Planar Transformer. Energies. 2022; 15(15):5609. https://doi.org/10.3390/en15155609
Chicago/Turabian StyleLee, Dae-Woo, Ji-Hoon Lim, Dong-In Lee, and Han-Shin Youn. 2022. "A High-Power-Density Active-Clamp Converter with Integrated Planar Transformer" Energies 15, no. 15: 5609. https://doi.org/10.3390/en15155609
APA StyleLee, D. -W., Lim, J. -H., Lee, D. -I., & Youn, H. -S. (2022). A High-Power-Density Active-Clamp Converter with Integrated Planar Transformer. Energies, 15(15), 5609. https://doi.org/10.3390/en15155609