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| Three-Winding Coupled Inductor and Its Design Method for Interleaved Vienna Rectifiers |
| Wang Kaiguo1, Gong Jinwu1, Pan Shangzhi1, Yuan Shixin2, Sun Zongchang2 |
1. Hubei Key Laboratory of Power Equipment &System Security for Integrated Energy Wuhan University Wuhan 430072 China;
2. Bull Group New Energy Division Shenzhen 518057 China |
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Abstract Interleaved Vienna rectifiers have been adopted extensively, enhancing power output capability, dispersing loss distribution, improving equivalent switching frequency, and reducing current ripple at the grid side. In the traditional separated scheme, the connecting inductor between the power grid and the converter generally comprises two magnetic components, a filter inductor and a tightly coupled inductor connected in series. The filter inductor is used to attenuate the high-frequency component of the grid current. The tightly coupled inductor forms a large equivalent inductance in the circulating current path to primarily reduce the amplitude of the circulating current between the bridge arms. Both are essential components of the interleaved Vienna rectifier. However, the utilization ratio of the tightly coupled inductor to the magnetic core is low, and two magnetic elements will occupy a larger PCB area. These two reasons make it difficult to improve the power density and efficiency of the interleaved system.
This paper proposes a three-winding coupled inductor that integrates the filter inductor and the coupled inductor on a single magnetic core. The flux in the magnetic core is evenly distributed, and the number of turns of the winding is reduced by reusing the magnetic core and the winding. Firstly, the structure of the proposed three-winding coupled inductor is given, and its equivalent circuit model is analyzed to obtain the relationship between its equivalent fundamental inductance, equivalent circulating inductance, and the self-inductance and mutual inductance of each winding. Secondly, the magnetic circuit model is analyzed to obtain the relationship between each winding’s self and mutual inductances and each magnetic circuit’s magnetic resistance. Then, the design method is given considering the air leakage path, and a three-winding coupled inductor with a rated current of 60 A (RMS value) is designed. Compared with the traditional separated scheme and the two-winding weakly coupled inductor scheme, the DC resistance of the designed three-winding coupled inductor is reduced by 35% and 11%, respectively, with the filter capacity, core volume, core saturation, and winding current density unchanged. The 40 kW three-phase Vienna rectifier using the three-winding coupled inductor achieves a maximum efficiency of 98.5%.
In view of the low utilization of the magnetic core of the tightly coupled inductor in the interleaved Vienna rectifier, this paper proposes a three-winding coupled inductor using integrated magnetic. The proposed inductor reduces losses and improves the power density of the device. Finite element simulation has proved the feasibility and effectiveness of the three-winding coupled inductor. The experiment on the prototype of an interleaved three-phase Vienna rectifier with a rated power of 40 kW proves that the designed three-winding coupled inductor has lower loss than the traditional separated scheme and the two-winding weakly coupled inductor scheme.
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Received: 02 December 2024
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2025, Vol. 40 
