Overview of Planar Magnetics for High-frequency Resonant Converters

Yue Liu; Yufeng Song; Dingfan Hu; Yang Li; Zuoqian Zhang; Hongfei Wu

doi:10.23919/CJEE.2022.000039

Chinese Journal of Electrical Engineering 2022, 8(4): 61-78 https://doi.org/10.23919/CJEE.2022.000039

Open Access | Issue | Published: 31 December 2022

Overview of Planar Magnetics for High-frequency Resonant Converters

Show Author's Information Hide Author's Information Yue Liu, Yufeng Song, Dingfan Hu, Yang Li, Zuoqian Zhang, Hongfei Wu(

)

Department of Electrical Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing 211106, China

Keywords:

Planar magnetics, resonant converter, matrix transformer, magnetic integration, PCB winding, loss model, loss measurement, CM noise suppression

Cite this article:

Liu Y, Song Y, Hu D, et al. Overview of Planar Magnetics for High-frequency Resonant Converters. Chinese Journal of Electrical Engineering, 2022, 8(4): 61-78. https://doi.org/10.23919/CJEE.2022.000039

Download citation

EndNote(RIS)

BibTeX

272

Views

Downloads

Citations

Crossref

N/A

WoS

Scopus

CSCD

Abstract Full text About this article

Abstract

With the continuous development of power supplies toward miniaturization, light weights, and high levels of integration, research on high-frequency resonant conversion based on planar magnetics is becoming extensive. Combining the soft-switching characteristics of resonant converters with those of wide bandgap devices, the switching frequency can be increase to the MHz range, and the power density of the entire system can be improved considerably. However, higher switching frequencies impose new requirements for the structural design, loss distribution, and common mode (CM) noise suppression of passive magnetic components. Herein, a thorough survey of the-state-of-the-art of planar magnetics in high-frequency resonant converters is conducted. Printed circuit board winding-based planar magnetics, magnetic integration, and power-loss optimization strategies are summarized in detail. Suppression methods for CM noise in high-frequency planar magnetics are also clarified and discussed. An insight view into the future development of planar magnetics for high-frequency resonant converters is presented.

Full text

Abstract

Full text

Outline

About this article

Overview of Planar Magnetics for High-frequency Resonant Converters

Show Author's information Hide Author's Information Yue Liu, Yufeng Song, Dingfan Hu, Yang Li, Zuoqian Zhang, Hongfei Wu(

)

Department of Electrical Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing 211106, China

Abstract

Keywords: Planar magnetics, resonant converter, matrix transformer, magnetic integration, PCB winding, loss model, loss measurement, CM noise suppression

References(87)

[1]

F C Lee, Q Li, A Nabih. High-frequency resonant converters: An overview on the magnetic design and control methods. IEEE Journal of Emerging and Selected Topics in Power Electronics, 2021, 9(1): 11-23.

DOI Google Scholar

[2]

J D van Wyk, F C Lee. On a future for power electronics. IEEE Journal of Emerging and Selected Topics in Power Electronics, 2021, 1(2): 59-72.

DOI Google Scholar

[3]

B Zhao, Q Song, W Liu, et al. Overview of dual-active-bridge isolated bidirectional DC-DC converter for high-frequency-link power-conversion system. IEEE Transactions on Power Electronics, 2014, 29(8): 4091-4106.

DOI Google Scholar

[4]

R C N Pilawa-Podgurski, A D Sagneri, J M Rivas, et al. Very-high-frequency resonant boost converters. IEEE Transactions on Power Electronics, 2009, 24(6): 1654-1665.

DOI Google Scholar

[5]

Y Wang, O Lucia, Z Zhang, et al. A review of high frequency power converters and related technologies. IEEE Open Journal of the Industrial Electronics Society, 2020, 1: 247-260.

DOI Google Scholar

[6]

K I Hwu, W C Yen, Y H Chen. Digital control of isolated two-stage DC-DC converter with synchronization considered. 2009 IEEE International Symposium on Industrial Electronics, July 5-8, 2009, Seoul, South Korea. Piscataway: IEEE, 2009: 1598-1603.

DOI

[7]

M Fu, C Fei, Y Yang, et al. A GaN-based DC-DC module for railway applications: Design consideration and high-frequency digital control. IEEE Transactions on Industrial Electronics, 2020, 67(2): 1638-1647.

DOI Google Scholar

[8]

E Cardelli, L Fiorucci, E D Torre. Estimation of MnZn ferrite core losses in magnetic components at high frequency. IEEE Transactions on Magnetics, 2001, 37(4): 2366-2368.

DOI Google Scholar

[9]

A Stadler, M Albach. The influence of the winding layout on the core losses and the leakage inductance in high frequency transformers. IEEE Transactions on Magnetics, 2006, 42(4): 735-738.

DOI Google Scholar

[10]

M T Quirke, J J Barrett, M Hayes. Planar magnetic component technology-A review. IEEE Transactions on Components, 1992, 15(5): 884-892.

DOI Google Scholar

[11]

G François, F Baudart, B Dehez. Analytical estimation of eddy current losses in PCB winding for the optimal sizing of PM slotless motor. 2019 IEEE International Electric Machines & Drives Conference (IEMDC), May 12-15, 2014, San Diego, CA, USA. Piscataway: IEEE, 2019: 862-869.

DOI

[12]

L A R Tria, D Zhang, J E Fletcher. Planar PCB transformer model for circuit simulation. IEEE Transactions on Magnetics, 2016, 52(7): 1-4.

DOI Google Scholar

[13]

D Huang, S Ji, F C Lee. LLC resonant converter with matrix transformer. IEEE Transactions on Power Electronics, 2014, 29(8): 4339-4347.

DOI Google Scholar

[14]

C Fei, F C Lee, Q Li. High-efficiency high-power-density LLC converter with an integrated planar matrix transformer for high-output current applications. IEEE Transactions on Industrial Electronics, 2017, 64(11): 9072-9082.

DOI Google Scholar

[15]

M H Ahmed, A Nabih, F C Lee, et al. Low-loss integrated inductor and transformer structure and application in regulated LLC converter for 48-V bus converter. IEEE Journal of Emerging and Selected Topics in Power Electronics, 2020, 8(1): 589-600.

DOI Google Scholar

[16]

Y Liu, H Wu, J Zou, et al. CLL resonant converter with secondary side resonant inductor and integrated magnetics. IEEE Transactions on Power Electronics, 2021, 36(10): 11316-11325.

DOI Google Scholar

[17]

M K Ranjram, D J Perreault. A 380-12 V, 1-kW, 1-MHz converter using a miniaturized split-phase, fractional-turn planar transformer. IEEE Transactions on Power Electronics, 2022, 37(2): 1666-1681.

DOI Google Scholar

[18]

M D’Antonio, S Chakraborty, A Khaligh. Planar transformer with asymmetric integrated leakage inductance using horizontal air gap. IEEE Transactions on Power Electronics, 2021, 36(12): 14014-14028.

DOI Google Scholar

[19]

A Nabih, Q Li, F C Lee. Magnetic integration of four-transformer matrix with high controllable leakage inductance using a five-leg magnetic. 2022 IEEE Applied Power Electronics Conference and Exposition (APEC), March 21-25, 2022, Phoenix, AZ, USA. Piscataway: IEEE, 2022: 693-700.

DOI

[20]

M Li, Z Ouyang, M A E Andersen. High-frequency LLC resonant converter with magnetic shunt integrated planar transformer. IEEE Transactions on Power Electronics, 2019, 34(3): 2405-2415.

DOI Google Scholar

[21]

E Orietti, P Mattavelli, G Spiazzi, et al. Current sharing in three-phase LLC interleaved resonant converter. 2009 IEEE Energy Conversion Congress and Exposition, Sept. 21-24, 2009, San Jose, CA, USA. Piscataway: IEEE, 2009: 1145-1152.

DOI

[22]

C Fei, R Gadelrab, Q Li, et al. High-frequency three-phase interleaved LLC resonant converter with GaN devices and integrated planar magnetics. IEEE Journal of Emerging and Selected Topics in Power Electronics, 2019, 7(2): 653-663.

DOI Google Scholar

[23]

R Gadelrab, F C Lee, Q Li. Three-phase interleaved LLC resonant converter with integrated planar magnetics for telecom and server application. 2020 IEEE Applied Power Electronics Conference and Exposition (APEC), March 15-19, 2020, New Orleans, LA, USA. Piscataway: IEEE, 2020: 512-518.

DOI

[24]

B Li, Q Li, F C Lee. High frequency PCB winding transformer with integrated inductors for a bi-directional resonant converter. IEEE Transactions on Power Electronics, 2018, 34(7): 6123-6135.

DOI Google Scholar

[25]

J Li, H Wu, W Hua, et al. Matrix inductor-transformer integration and optimization design for CLLC bidirectional resonant converter. Proceedings of the CSEE, 2022, 42(10): 3720-3728.

Google Scholar

[26]

K Zhang, T X Wu, J Shen, et al. Modeling and design optimization of planar power transformer for aerospace application. Proceedings of the IEEE 2009 National Aerospace & Electronics Conference (NAECON), July 21-23, 2009, Dayton, OH, USA. Piscataway: IEEE, 2009: 116-120.

DOI

[27]

C Ropoteanu, P Svasta, C Ionescu. A study of losses in planar transformers with different layer structure. 2017 IEEE 23rd International Symposium for Design and Technology in Electronic Packaging (SIITME), Oct. 27-29, 2017, Constanta, Romania. Piscataway: IEEE, 2017: 255-258.

DOI

[28]

R Yu, T Chen, P Liu, et al. A 3-D winding structure for planar transformers and its applications to LLC resonant converters. IEEE Journal of Emerging and Selected Topics in Power Electronics, 2021, 9(5): 6232-6247.

DOI Google Scholar

[29]

W Chen, Y Yan, Y Hu, et al. Model and design of PCB parallel winding for planar transformer. IEEE Transactions on Magnetics, 2003, 39(5): 3202-3204.

DOI Google Scholar

[30]

S Li, E Rong, Q Min, et al. A half-turn transformer with symmetry magnetic flux for high-frequency-isolated DC/DC converters. IEEE Transactions on Magnetics, 2018, 33(8): 6467-6470.

DOI Google Scholar

[31]

Y Liu, K Chen, C Chen, et al. Quarter-turn transformer design and optimization for high power density 1-MHz LLC resonant converter. IEEE Trans. Ind. Electron., 2020, 67(2): 1580-1591.

DOI Google Scholar

[32]

S Wang, H Wu, F C Lee, et al. Integrated matrix transformer with optimized PCB winding for high-efficiency high-power-density LLC resonant converter. 2019 IEEE Energy Conversion Congress and Exposition (ECCE), September 29-October 3, 2019, Baltimore, MD, USA. Piscataway: IEEE, 2019: 6621-6627.

DOI

[33]

Y Jin, W Xie, N Yang, et al. High efficiency resonant DC/DC converter based on GaN device and planar transformer. 2020 IEEE 5th Information Technology and Mechatronics Engineering Conference (ITOEC), June 12-14, 2020, Chongqing, China. Piscataway: IEEE, 2020: 358-362.

DOI

[34]

P R Wilson, J N Ross, A D Brown. Modeling frequency-dependent losses in ferrite cores. IEEE Transactions on Magnetics, 2004, 40(3): 1537-1541.

DOI Google Scholar

[35]

I D Mayergoyz, G Friedman. Generalized Preisach model of hysteresis. IEEE Trans. on Magnetics, 1988, 24(1): 212-217.

DOI Google Scholar

[36]

D C Jiles, D L Atherton. Theory of ferromagnetic hysteresis. Journal of Magnetism and Magnetic Materials, 1986, 61: 48-60.

DOI Google Scholar

[37]

D Lin, P Zhou, W N Fu, et al. A dynamic core loss model for soft ferromagnetic and power ferrite materials in transient finite element analysis. IEEE Transactions on Magnetics, 2004, 40(2): 1318-1321.

DOI Google Scholar

[38]

C P Steinmetz. On the law of hysteresis. Transactions of the American Institute of Electrical Engineers, 1892, 9(1): 1-64.

DOI Google Scholar

[39]

J E Brittain. A Steinmemtz contribution to the AC power revolution. Proceedings of the IEEE, 1984, 72(2): 196-197.

DOI Google Scholar

[40]

J Reinert, A Brockmeyer, R W A A De Doncker. Calculation of losses in ferro- and ferrimagnetic materials based on the modified Steinmetz equation. IEEE Transactions on Industry Applications, 2001, 37(4): 1055-1061.

DOI Google Scholar

[41]

J Li, T Abdallah, C R Sullivan. Improved calculation of core loss with nonsinusoidal waveforms. Conference Record of the 2001 IEEE Industry Applications Conference (Cat. No.01CH37248), Sept. 30-Oct. 4, 2001, Chicago, IL, USA. Piscataway: IEEE, 2002: 2203-2210.

[42]

J Liu, T G Wilson, R C Wong, et al. A method for inductor core loss estimation in power factor correction applications. APEC. Seventeenth Annual IEEE Applied Power Electronics Conference and Exposition (Cat. No.02CH37335), March 10-14, 2002, Dallas, TX, USA. Piscataway: IEEE, 2002: 439-445.

[43]

K Venkatachalam, C R Sullivan, T Abdallah, et al. Accurate prediction of ferrite core loss with nonsinusoidal waveforms using only Steinmetz parameters. 2002 IEEE Workshop on Computers in Power Electronics, 2002. Proceedings., June 3-4, 2002, Mayaguez, PR, USA. Piscataway: IEEE, 2002: 36-41.

[44]

J Muhlethaler, J Biela, J W Kolar, et al. Improved core-loss calculation for magnetic components employed in power electronic systems. IEEE Transactions on Power Electronics, 2012, 27(2): 964-973.

DOI Google Scholar

[45]

A Brockmeyer. Experimental evaluation of the influence of DC-premagnetization on the properties of power electronic ferrites. Proceedings of Applied Power Electronics Conference. APEC’96, March 3-7, 1996, San Jose, CA, USA. Piscataway: IEEE, 2002: 454-460.

[46]

W K Mo, D K W Cheng, Y S Lee. Simple approximations of the DC flux influence on the core loss power electronic ferrites and their use in design of magnetic components. IEEE Transactions on Industrial Electronics, 1997, 44(12): 788-799.

DOI Google Scholar

[47]

J Ye, W Chen, J Wang. Research on the core loss model under PWM wave and DC bias excitations. Proceedings of the CSEE, 2015, 35(10): 2601-2606.

Google Scholar

[48]

E Dlala. Comparison of models for estimating magnetic core losses in electrical machines using the finite-element method. IEEE Trans. Magn, 2009, 45(2): 716-725.

DOI Google Scholar

[49]

A Rakotomatala, N Burais, P Auriol. A 2D semi-analytical method for the calculation of eddy current losses in transformer and inductance coils. 1994 Fifth International Conference on Power Electronics and Variable-Speed Drives, Oct. 26-28, 1994, Mayaguez, London, UK. Hertford: IET, 1994: 188-191.

DOI

[50]

P L Dowell. Effects of eddy currents in transformer windings. Proceedings of the Institution of Electrical Engineers, 1966, 113(8): 1387-1394.

DOI Google Scholar

[51]

J A Ferreira. Improved analytical modeling of conductive losses in magnetic components. IEEE Transactions on Power Electronics, 1994, 9(1): 127-131.

DOI Google Scholar

[52]

J A Ferreira. Appropriate modelling of conductive losses in the design of magnetic components. 21st Annual IEEE Conference on Power Electronics Specialists, 1990, San Antonio, TX, USA. Piscataway: IEEE, 2002: 780-785.

[53]

X Nan, C R Sullivan. An improved calculation of proximity-effect loss in high-frequency windings of round conductors. IEEE 34th Annual Conference on Power Electronics Specialist, 2003. PESC’03., June 15-19, 2003, Acapulco, Mexico. Piscataway: IEEE, 2003: 853-860.

[54]

A W Lotfi, F C Lee. Two dimensional field solutions for high frequency transformer windings. Proceedings of IEEE Power Electronics Specialist Conference–PESC’93, June 20-24, 1993, Seattle, WA, USA. Piscataway: IEEE, 2002: 1098-1104.

[55]

F Robert, P Mathys, J P Schauwers. A closed-form formula for 2-D ohmic losses calculation in SMPS transformer foils. IEEE Transactions on Power Electronics, 2001, 16(3): 437-444.

DOI Google Scholar

[56]

N H Kutkut. A simple technique to evaluate winding losses including two-dimensional edge effects. Proceedings of APEC 97-Applied Power Electronics Conference, Feb. 27-27, 1997, Atlanta, GA, USA. Piscataway: IEEE, 2002: 368-374.

[57]

K V Iyer, W P Robbins, K Basu, et al. Transformer winding losses with round conductors for duty-cycle regulated square waves. 2014 International Power Electronics Conference (IPEC-Hiroshima 2014 - ECCE ASIA), May 18-21, 2014, Hiroshima, Japan. Piscataway: IEEE, 2014: 3061-3066.

DOI

[58]

W Yuan, X Huang, P Meng, et al. An improved winding loss analytical model of Flyback transformer. 2010 Twenty-Fifth Annual IEEE Applied Power Electronics Conference and Exposition (APEC), Feb. 21-25, 2010, Palm Springs, CA, USA. Piscataway: IEEE, 2010: 433-438.

DOI

[59]

M Cui, X You, Y Li, et al. Planar transformer design in GaN based LLC resonant converter. 2014 International Power Electronics and Application Conference and Exposition, Nov. 5-8, 2014, Shanghai, China. Piscataway: IEEE, 2014: 1353-1357.

DOI

[60]

I Lope, C Carretero, J Acero, et al. AC power losses model for planar windings with rectangular cross-sectional conductors. IEEE Transactions on Power Electronics, 2014, 29(1): 23-28.

DOI Google Scholar

[61]

X Wang, L Wang, L Mao, et al. Improved analytical calculation of high frequency winding losses in planar inductors. IEEE 2018 Energy Conversion Congress and Expo, Sept. 23-27, 2018, Portland, OR, USA. Piscataway: IEEE, 2018: 4336-4340.

DOI

[62]

M Wu, L Wang, D Ahmed, et al. An accurate analytical model to evaluate the winding loss of a single-layer multi-turn planar air-core PCB-inductor. 2021 IEEE Energy Conversion Congress and Exposition (ECCE), Oct. 10-14, 2021, Vancouver, BC, Canada. Piscataway: IEEE, 2021: 5483-5487.

DOI

[63]

P Marketos, J P Hall, S E Zirka. Power loss measurement and prediction of soft magnetic powder composites magnetized under sinusoidal and nonsinusoidal excitation. IEEE Transactions on Magnetics, 2008, 44(11): 3847-3850.

DOI Google Scholar

[64]

J Ye, W Chen, J He. A differential method of high-frequency magnetics core loss test scheme. 2014 IEEE 5th International Symposium on Power Electronics for Distributed Generation Systems (PEDG), June 24-27, 2014, Galway. Piscataway: IEEE, 2014: 1-5.

[65]

J Wang,W Chen. Study of calorimetric method to measure loss of super low loss angle core. Advanced Technology of Electrical Engineering and Energy, 2012, 31(4): 6-9.

DOI Google Scholar

[66]

P Gradzki. Core loss characterization and design optimization of high-frequency power ferrite devices in power electronics applications. Blacksburg: Virginia Polytechnic Institute and State University, 1992.

[67]

F D Tan, J L Vollin, S M Cuk. A practical approach for magnetic core-loss characterization. IEEE Transactions on Power Electronics, 1995, 10(2): 124-130.

DOI Google Scholar

[68]

D R Turner, K J Binns, B N Shamsaddeen, et al. Accurate measurement of induction motor losses using balance calorimete. Electric Power Applications, 1991, 138(5): 233-242.

DOI Google Scholar

[69]

J Zhang, G Skutt, F C Lee. Some practical issues related to core loss measurement using impedance analyzer approach. Proceedings of IEEE Applied Power Electronics Conference, March 5-9, 1995, Hyatt Regency, Dallas, USA. Piscataway: IEEE, 1995: 547-553.

[70]

G R Skut, F C Lee. Some practical issues related to core loss measurement using impedance analyzer. Proceedings of 1995 IEEE Applied Power Electronics Conference and Exposition - APEC'95, March 5-9, 1995, Dallas, TX, USA. Piscataway: IEEE, 1995: 547-554.

[71]

D Y Chen. High-frequency core loss characteristics of amorphous magnetic alloy. Proceedings of the IEEE, 1981, 69(7): 853-855.

DOI Google Scholar

[72]

M S Lancarotte, C Goldemberg, A D A Penteado. Estimation of FeSi core losses under PWM or DC bias ripple voltage excitations. IEEE Transactions on Energy Conversion, 2005, 20(2): 367-372.

DOI Google Scholar

[73]

C Yan,J He,X Guo. Influence of different excitation waveforms on ferrite core loss. Journal of Magnetic Materials and Devices, 2011, 42(2): 37-42.

DOI Google Scholar

[74]

D Hou, M Mu, F C Lee, et al. New high-frequency core loss measurement method with partial cancellation concept. IEEE Transactions on Power Electronics, 2017, 32(4): 2987-2994.

DOI Google Scholar

[75]

J Ye, W Chen. The method and device based on the differential power for measurement of high-frequency core losses. Proceedings of the CSEE, 2017, 37(16): 4834-4841, 4909.

Google Scholar

[76]

C R Sullivan. Computationally efficient winding loss calculation with multiple windings, arbitrary waveforms, and two-dimensional or three-dimensional field geometry. IEEE Trans. on Power Electronics, 2001, 16(1): 142-150.

DOI Google Scholar

[77]

J Ye, W Chen. A novel evaluation and test method for gapped magnetics high-frequency winding losses. Proceedings of the CSEE, 2015, 35(7): 1749-1755.

Google Scholar

[78]

J Wang, W Chen. Deduction of copper loss from core loss under square wave excitation. Journal of Nanchang University, 2012, 34(3): 279-282.

DOI Google Scholar

[79]

Y Hao, W Eberle, Y Liu. A practical copper loss measurement method for the planar transformer in high-frequency switching converters. IEEE Transactions on Industrial Electronics, 2007, 54(4): 2276-2287.

DOI Google Scholar

[80]

J Ye, W Chen, R Zheng, et al. The direct measurement method of magnetic winding losses. Proceedings of the CSEE, 2018, 38(5): 1369-1374.

Google Scholar

[81]

D Fu, S Wang, P Kong, et al. Novel techniques to suppress the common-mode EMI noise caused by transformer parasitic capacitances in DC-DC converters. IEEE Transactions on Industrial Electronics, 2013, 60(11): 4968-4977.

DOI Google Scholar

[82]

Y P Chan, B M H Pong, N K Poon, et al. Common-mode noise cancellation by an antiphase winding in multilayer isolated planar transformer. IEEE Transactions on Electromagnetic Compatibility, 2014, 56(1): 67-73.

DOI Google Scholar

[83]

S Zhang, X Wu. Analysis and suppression of conducted EMI emissions for front-end LLC resonant DC/DC converters. IEEE Transactions on Power Electronics, 2019, 34(2): 1032-1037.

DOI Google Scholar

[84]

D Fu, P Kong, S Wang, et al. Some practical issues related to core loss measurement using impedance analyzer approach. 2008 IEEE Power Electronics Specialists Conference, June 15-19, 2008, Rhodes, Greece. Piscataway: IEEE, 2008: 1144-1150.

[85]

Y Han, G Li, H Shi, et al. Analysis and suppression of common-mode EMI noise in 1 MHz 380 V-12 V DCX converter with low NFoM devices. IEEE Transactions on Power Electronics, 2021, 36(7): 7903-7931.

DOI Google Scholar

[86]

Y Yang, D Huang, F C Lee, et al. Analysis and reduction of common mode EMI noise for resonant converters. 2014 IEEE Applied Power Electronics Conference and Exposition - APEC 2014, March 16-20, 2014, Fort Worth, TX, USA. Piscataway: IEEE, 2014: 566-571.

DOI

[87]

C Fei, Y Yang, Q Li, et al. Shielding technique for planar matrix transformers to suppress common-mode EMI noise and improve efficiency. IEEE Transactions on Industrial Electronics, 2018, 65(2): 1263-1272.

DOI Google Scholar

About this article

Publication history

Rights and permissions

Publication history

Received: 05 July 2022

Revised: 22 July 2022

Accepted: 29 July 2022

Published: 31 December 2022

Issue date: December 2022

Overview of Planar Magnetics for High-frequency Resonant Converters

Overview of Planar Magnetics for High-frequency Resonant Converters

Abstract

References(87)

Publication history

Copyright

Rights and permissions