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

Abstract
Figure/Table
References (0)
Related Citation (15)

Download: PDF (8630 KB) HTML (1 KB)
Export: BibTeX | EndNote (RIS)

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

Received: 04 January 2024

PACS:

TM46

	Service

	E-mail this article
	Add to my bookshelf
	Add to citation manager
	E-mail Alert
	RSS
	Articles by authors
	Cheng He
	Xu Kai
	Li Pengsheng
	Qi Naiju
	Yu Dongsheng

Cite this article:

Cheng He,Xu Kai,Li Pengsheng等. Design and Optimization of Three-Phase CLLC Resonant Converter with Magnetic Integrated Planar Transformer[J]. Transactions of China Electrotechnical Society, 2024, 39(12): 3774-3786.

URL:

https://dgjsxb.ces-transaction.com/EN/10.19595/j.cnki.1000-6753.tces.240017 OR https://dgjsxb.ces-transaction.com/EN/Y2024/V39/I12/3774

[1] 王晓姬, 王道涵, 王柄东, 等. 电动汽车驱动/充电一体化系统及其控制策略综述[J]. 电工技术学报, 2023, 38(22): 5940-5958.
Wang Xiaoji, Wang Daohan, Wang Bingdong, et al.A review of drive-charging integrated systems and control strategies for electric vehicles[J]. Transa- ctions of China Electrotechnical Society, 2023, 38(22): 5940-5958.
[2] 赵子先, 康龙云, 于玮, 等. 基于简化时域模型的CLLC直流变换器参数设计[J]. 电工技术学报, 2022, 37(5): 1262-1274.
Zhao Zixian, Kang Longyun, Yu Wei, et al.Parameter design method of CLLC DC-DC converter based on simplified time domain model[J]. Transactions of China Electrotechnical Society, 2022, 37(5): 1262-1274.
[3] 丁超, 李勇, 姜利, 等. 电动汽车直流充电系统LLC谐振变换器软开关电压边界分析[J]. 电工技术学报, 2022, 37(1): 3-11.
Ding Chao, Li Yong, Jiang Li, et al.Analysis of soft switching voltage boundary of LLC resonant converter for EV DC charging system[J]. Transa- ctions of China Electrotechnical Society, 2022, 37(1): 3-11.
[4] 朱小全, 刘康, 叶开文, 等. 基于SiC器件的隔离双向混合型LLC谐振变换器[J]. 电工技术学报, 2022, 37(16): 4143-4154.
Zhu Xiaoquan, Liu Kang, Ye Kaiwen, et al.Isolation bidirectional hybrid LLC converter based on SiC MOSFET[J]. Transactions of China Electrotechnical Society, 2022, 37(16): 4143-4154.
[5] 李加明, 任小永, 周治成, 等. 基于谐振网络优化的双向LLC-DCX多模块并联系统均流优化研究[J].电工技术学报, 2023, 38(10): 2720-2730, 2756.
Li Jiaming, Ren Xiaoyong, Zhou Zhicheng, et al.Research on current sharing optimization of bidirectional LLC-DCX multi-module parallel system based on resonant network optimization[J]. Transactions of China Electrotechnical Society, 2023, 38(10): 2720-2730, 2756.
[6] 王议锋, 陈晨, 陈博, 等. LLC 谐振变换器的变压器绕组优化设计[J]. 电工技术学报, 2022, 37(5): 1252-1261.
Wang Yifeng, Chen Chen, Chen Bo, et al.Optimization design of transformer windings of LLC converter[J]. Transactions of China Electrotechnical Society, 2022, 37(5): 1252-1261.
[7] 李彬彬, 王志远, 张丙旭, 等. 采用辅助变压器的可调压谐振零电压零电流开关变换器[J]. 电力系统自动化, 2022, 46(7): 160-169.
Li Binbin, Wang Zhiyuan, Zhang Bingxu, et al.Voltage- regulatable resonant zero-voltage zero-current switching converter with auxiliary transformer[J]. Automation of Electric Power Systems, 2022, 46(7): 160-169.
[8] Zhang Qing, Zhang Xiaoyong, Rao Peinan, et al.Analysis and design of bidirectional isolation converter based on full-bridge CLLC[C]//2020 IEEE Vehicle Power and Propulsion Conference (VPPC), Gijon, Spain, 2020: 1-6.
[9] 李浩然, 崔超辉, 王生东, 等. 基于二阶拟合模型的SiC双向LLC数字同步整流控制[J]. 电工技术学报, 2022, 37(24): 6191-6203.
Li Haoran, Cui Chaohui, Wang Shengdong, et al.Two-order fitting model-based digital synchronous rectifier control for SiC bidirectional LLC converter[J]. Transactions of China Electrotechnical Society, 2022, 37(24): 6191-6203.
[10] 李俊杰, 吴红飞, 花文敏, 等. CLLC双向谐振变换器电感-变压器矩阵式一体化集成与优化设计[J]. 中国电机工程学报, 2022, 42(10): 3720-3729.
Li Junjie, Wu Hongfei, Hua Wenmin, et al.Integrated inductor-transformer matrix and optimization design of CLLC bidirectional resonant converter[J]. Pro- ceedings of the CSEE, 2022, 42(10): 3720-3729.
[11] Martinez W, Noah M, Endo S, et al.Three-phase LLC resonant converter with integrated magnetics[C]// 2016 IEEE Energy Conversion Congress and Exposition (ECCE), Milwaukee, USA, 2016: 1-8.
[12] Núñez J I, Barrado A, Lázaro A, et al.Three-phase CLLLC resonant converters[C]//2021 IEEE 15th International Conference on Compatibility, Power Electronics and Power Engineering (CPE-POWERENG), Florence, Italy, 2021: 1-6.
[13] Li Bin, Li Qiang, Lee F C.A WBG based three phase 12.5 kW 500 kHz CLLC resonant converter with integrated PCB winding transformer[C]//2018 IEEE Applied Power Electronics Conference and Exposition (APEC), San Antonio, TX, USA, 2018: 469-475.
[14] Pham P H, Nabih A, Wang Shuo, et al.11-kW high-frequency high-density bidirectional OBC with PCB winding magnetic design[C]//2022 IEEE Applied Power Electronics Conference and Exposition (APEC), Houston, TX, USA, 2022: 1176-1181.
[15] Jin Feng, Nabih A, Li Qiang, et al.A three phase CLLC converter with improved planar integrated transformer for fast charger applications[C]//2021 IEEE Fourth International Conference on DC Microgrids (ICDCM), Arlington, VA, USA, 2021: 1-5.
[16] Arshadi S A, Ordonez M, Eberle W.Current-sharing worst-case analysis of three-phase CLLC resonant converters[J]. IEEE Transactions on Power Elec- tronics, 2022, 37(3): 3099-3110.
[17] 杨玉岗, 武艳秋, 孙晓钰, 等. 交错并联双向CLLC型谐振变换器中U+U型磁集成变压器的设计[J]. 电工技术学报, 2021, 36(2): 282-291.
Yang Yugang, Wu Yanqiu, Sun Xiaoyu, et al.Design of U+U type magnetic integrated transformer in interlaced bidirectional CLLC resonant converter[J]. Transactions of China Electrotechnical Society, 2021, 36(2): 282-291.
[18] 张缙, 刘智, 刘意, 等. 基于智能算法的双面散热SiC功率模块多目标优化设计[J]. 电工技术学报, 2023, 38(20): 5515-5529.
Zhang Jin, Liu Zhi, Liu Yi, et al.Research on multi-objective optimization design of double- sided cooling SiC power module based on intelligent algorithml[J]. Transactions of China Electrotechnical Society, 2023, 38(20): 5515-5529.
[19] 赵方玮, 李艳, 魏超, 等. GaN器件动态导通电阻精确测试与影响因素分析[J]. 电工技术学报, 2022, 37(18): 4664-4675.
Zhao Fangwei, Li Yan, Wei Chao, et al.Accurate measurement of dynamic on-resistance of GaN devices and affecting factor analysis[J]. Transa- ctions of China Electrotechnical Society, 2022, 37(18): 4664-4675.
[20] 杨勇, 宋大威, 顾占彪, 等. 星载1MHz GaN LLC变换器低反向导通损耗控制[J]. 电工技术学报, 2022, 37(24): 6183-6190.
Yang Yong, Song Dawei, Gu Zhanbiao, et al.Low reverse conduction loss control for 1MHz GaN-based LLC converter used in satellite application[J]. Transactions of China Electrotechnical Society, 2022, 37(24): 6183-6190.
[21] 王议锋, 刘瑞欣, 韩富强, 等. CLTLC多谐振变换器的磁集成方法[J]. 电工技术学报, 2022, 37(2): 380-388.
Wang Yifeng, Liu Ruixin, Han Fuqiang, et al.Magnetic integration method for CLTLC multi- resonant converter[J]. Transactions of China Electrotechnical Society, 2022, 37(2): 380-388.
[22] Li Bin, Li Qiang, Lee F C.High-frequency PCB winding transformer with integrated inductors for a bi-directional resonant converter[J]. IEEE Transactions on Power Electronics, 2019, 34(7): 6123-6135.
[23] Li Bin, Li Qiang, Lee F C.A novel PCB winding transformer with controllable leakage integration for a 6.6kW 500kHz high efficiency high density bi- directional on-board charger[C]//2017 IEEE Applied Power Electronics Conference and Exposition (APEC), Tampa, FL, USA, 2017: 2917-2924.
[24] Noah M, Umetani K, Endo S, et al.A Lagrangian dynamics model of integrated transformer incorporated in a multi-phase LLC resonant converter[C]//2017 IEEE Energy Conversion Congress and Exposition (ECCE), Cincinnati, OH, USA, 2017: 3781-3787.
[25] Huang Hong.FHA-based voltage gain function with harmonic compensation for LLC resonant converter[C]// 2010 Twenty-Fifth Annual IEEE Applied Power Electronics Conference and Exposition (APEC), Palm Springs, CA, USA, 2010: 1770-1777.