电流源型双有源桥DC-DC变换器磁集成研究

Research on Magnetic Integration of Current-fed Dual Active Bridge DC-DC Converter

  • 摘要: 电流源型双有源桥(Current-fed dual active bridge,CF-DAB) DC-DC变换器包含两个输入直流电感、一个串联电感及一个变压器等多个磁性元件,这些磁性元件的数量及体积限制了CF-DAB DC-DC变换器的功率密度,因此采用磁集成技术将多个磁性元件集成至单一磁心中,以提升系统的功率密度。首先,基于零电压关断(Zero-voltage switching,ZVS)条件和最大输出功率要求,完成了输入直流电感和串联电感的参数设计;随后,创新性地提出了一种新型磁集成结构及其设计方法,并给出了完整的设计流程与具体设计实例。其次,采用ANSYS Maxwell电磁仿真平台对多组磁心和绕组参数进行仿真分析,最终筛选出兼具低损耗和小体积特性的最优参数组合。最后,通过搭建试验样机验证了所提磁集成结构和设计方法的可行性与有效性。试验与仿真结果表明,与传统分立磁心方案相比,所提集成磁心设计在多个性能指标上均展现出显著优势——磁心总体积减小了36.4 cm3,总损耗降低了1.6 W,同时峰值效率提升至98.37%。仿真与试验数据的一致性充分验证了所提磁集成结构及其设计方法的可行性与有效性。

     

    Abstract: The current-fed dual-active-bridge(CF-DAB) DC-DC converter contains multiple magnetic components, including two input DC inductors, one series inductor, and a transformer. The quantity and volume of these magnetic components limit the power density of CF-DAB converters. Therefore, magnetic integration technology is adopted to integrate multiple magnetic components into a single core to improve system power density. First, the parameter design of the input DC inductors and series inductor is completed based on zero-voltage switching(ZVS) conditions and maximum output power requirements. Subsequently, an innovative magnetic integration structure and its design method are proposed, with detailed design procedures and a specific design example provided. Then, ANSYS Maxwell is employed to simulate multiple sets of core and winding parameters, from which an optimal configuration with both low loss and small volume is selected. Finally, a prototype is built to experimentally verify the feasibility and effectiveness of the proposed magnetic integration structure and design method. Both experimental and simulation results show that compared with the conventional discrete magnetic core solution, the proposed integrated magnetic design demonstrates significant advantages in multiple performance metrics: the total core volume is reduced by 36.4 cm3, total losses are decreased by 1.6 W, and the peak efficiency reaches 98.37%. The consistency between simulation and experimental results fully validates the feasibility and effectiveness of the proposed magnetic integration structure and design method.

     

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