三相CLLC谐振变换器磁集成平面变压器设计与优化

doi:10.19595/j.cnki.1000-6753.tces.240017

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摘要

三相CLLC谐振变换器凭借其高效率、大容量、低器件应力等优势而受到广泛关注。然而,多相结构的磁性元件数量多、体积大,是制约功率变换器尺寸的主要因素。随着宽禁带（WBG）半导体器件的出现,功率变换器的开关频率显著提高,这也为印制电路板（PCB）绕组的使用提供了有利条件。与传统绕线式绕组相比,PCB绕组的扁平特性更适用于平面磁性元件。此外,由于高频带来的低电感需求也使得基于PCB绕组的平面磁性元件更有利于实现集成。该文提出一种新型的基于PCB绕组的电感和变压器的集成结构,详细分析磁心结构的磁路模型,并给出集成磁件的优化设计方法,最后通过搭建一台基于SiC器件的800 V/10 kW的实验样机进行验证。实验结果表明,该集成方案可有效减小变换器的体积和损耗,具有高功率密度和高效率。

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关键词 ：三相CLLC谐振变换器, PCB绕组, 磁集成, 优化设计

Abstract：

The three-phase CLLC resonant converter has attracted widespread attention due to its high efficiency, high capacity, and low device stress. However, the large number and volume of magnetic components in multi-phase structures are the main factors limiting the size of power converters. With the development of wide band gap devices, the switching frequency of power converters has significantly increased, providing favorable conditions for the utilization of PCB windings. The flat characteristics of PCB windings are more suitable for planar magnetic components. Additionally, the low inductance demand brought about by high frequencies also makes PCB-based planar magnetic components more advantageous for integration. Some integrated schemes have achieved the integration of all magnetic elements and the controllability of leakage inductance, but their structure resulted in the asymmetry of magnetic resistance. Some other studies have proposed a symmetrical integrated scheme that achieved the complete symmetry of magnetic resistance, but the leakage inductance obtained by the integration method was restricted.
In this paper, a “cylindrical” planar magnetic core structure based on a three-phase CLLC resonant converter is proposed to realize the integration of magnetic elements and improve the power density of the system. The magnetic core structure is entirely symmetrical in space, achieving the symmetry of magnetic resistance and enhancing the stability of the system. Fig.A1 shows our topology structure and integrated magnetic core structure (including the planar structure diagram). The proposed integrated magnetics consists of the magnetic lid, magnetic plate, PCB winding, and magnetic base.

Fig.A1 Structure of the topology and integrated magnetics
Firstly, according to the equivalent circuit of the three-phase CLLC resonant converter, its gain characteristics are derived, and the prototype parameters are reasonably designed according to the relationship between the gain curve and K, Q values. Then, based on the proposed integrated magnetic core structure, a magnetic circuit model is established. The relationship between the resonant inductance L_r, the excitation inductance L_m, the inductance coefficient K, the winding turns N₁ and N₂, and the magnetic resistance R_g is analyzed. Next, a loss model and an optimization procedure of the transformer is built to achieve the lowest loss of the transformer. Finally, an 800 V/10 kW prototype platform was built. Comparative experiments were conducted with the “square” integrated magnetics and the proposed “cylindrical” magnetics, as shown in Fig.A2.

Fig.A2 “square” integrated magnetics and the “cylindrical” magnetics
The following conclusions can be drawn from the experiments. (1) Compared to the “square” integrated magnetics, the proposed integrated magnetics shows smaller imbalances among the three-phase resonant currents, achieving better system stability. (2) The proposed integrated magnetics maintains higher efficiency than the “square” integrated magnetics, even with a smaller volume and footprint. It demonstrates that the proposed structure possesses high power density and efficiency. (3) The proposed integrated magnetics achieves an efficiency of 97.5% at full load, validating the rationality and feasibility of the proposed magnetic core structure.

Key words： Three-phase CLLC resonant converter PCB winding integrated magnetics optimal design

收稿日期: 2024-01-04

PACS:

TM46

基金资助:

江苏省自然科学基金（BK20231500）和徐州市基础研究计划（KC22046）资助项目

通讯作者: 徐恺男,1998年生,硕士研究生,研究方向为车载高功率密度充电器。E-mail：976671368@qq.com

作者简介: 程鹤男,1987年生,副教授,硕士生导师,研究方向为新能源发电技术、新能源电动汽车、电力电子变换器、车载高功率密度充电器、新型电机设计、电机驱动系及其控制等。E-mail：chenghecumt@163.com

引用本文:

程鹤, 徐恺, 李朋圣, 齐乃菊, 于东升. 三相CLLC谐振变换器磁集成平面变压器设计与优化[J]. 电工技术学报, 2024, 39(12): 3774-3786. Cheng He, Xu Kai, Li Pengsheng, Qi Naiju, Yu Dongsheng. Design and Optimization of Three-Phase CLLC Resonant Converter with Magnetic Integrated Planar Transformer. Transactions of China Electrotechnical Society, 2024, 39(12): 3774-3786.

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