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e
l
(a) air-gapped core magnetic circle (b) equivalent magnetic conductance
Fig.7. Representation of an EE air-gapped magnetic core
Calculating the equivalent magnetic conductivity of the
air-gapped core:
2 1
2 1
2
2
G G
G G
G
+
= (4)
) ( ) (
0
1
+ +
=
F C
G (5)
2
) ( ) (
0
2
+ +
=
E A C
G (6)
e
e r
M
l
A
G
=
0
(7)
M
M
G G
G G
G
+
(8)
Calculating the length of air-gap and the turns of inductor
winding:
G N L
Lr r
=
2
(9)
e
r
Lr
l
B B
i N + =
0
max
0
max
max
2 (10)
F C A
e
= (11)
) ( 2
2
) (
D B
E A
l
e
+ +
+
= (12)
Where
m H u
o
/ 10 4
7
= is the free air magnetic permeability;
r
u is the relative magnetic permeability of the soft-ferrite
magnetic core;
is the air-gap length;
Lr
N is the turns of inductor winding;
A i 140
max
= is the highest value of resonant current;
mT B 300
max
= is the magnetic flux density which is
chosen at the highest resonant current point;
Substituting relevant value for the symbol in the above
equations (4-12), two anticipant parameters can be solved.
After simplification of the results because the number of
winding turns should be integral:
6 =
Lr
N mm 73 . 1 =
Winding conductor selection and distribution: there is a
prudential selection among copper foil, solid round wire, and
Litz-wire based on the penetration depth at the given
frequency ( mm 2955 . 0 = ). For an air-gapped conductor,
there exists a significant fringing magnetic field which will
cause a winding ac resistance to be higher than the dc
resistance, mainly caused by the skin effect and proximity
effect. For the reason of high virtual value of resonant current
(70A) and short winding length, the winding current density is
selected to
2
6 mm A . The distribution of inductor winding
turns is depicted as follow:
a) for foil winding case, foil width is equal to winding
bobbin width, the turns is winded layer by layer.
IAS 2005 1478 0-7803-9208-6/05/$20.00 2005 IEEE
b) for solid round wire winding case: 150 twisted strands
(specification of the solid round wire is AGW29) combine the
winding bundle is used for this case, and is winded turn by
turn in one layer.
c) for Litz-wire winding case: 12 twisted Litz-wire bundles
(specification is 38 130 AGW and is twisted on itself) build
the final Litz-wire bundle, and is winded turn by turn in one
layer.
Experimental results will be given for each of conductors,
also an explanation about how the skin effect and proximity
effect do in fabricated inductors is described.
B. Resonant capacitor design
Utilizing the simulated results, virtual value of resonant
current which is passing through the resonant capacitor is also
equal to 70A, and using the relationship as bellow:
2 2
2
1
2
1
Cr r Lr r
u C i L = (13)
The maximal voltage of resonant capacitor by solving
(13):
V u
Cr
300
max
(14)
Table II. CHARACTER OF 941C SERIES CAPACITORS
Voltage
rank
Capacitor
value
peak
I
(A)
RMS
I
(A)
941C6P15K 0.15u 20 2.8
941C6P22K 0.22u 43 4.9
941C6P47K
600 (DC)
275 (AC)
0.47u 92 7.6
941C12P15K 0.15u 171 8.3
941C12P22K 0.22u 251 9.2
941C12P47K 0.47u 301 10.9
941C12P68K 0.68u 435 13.0
941C12W1K
1200 (DC)
500 (AC)
1.0u 754 19.7
For this huge virtual value current application case, the
CDE capacitor accords with our demand [14]. Table II shows
the character of 941C series CDE capacitors, three crucial
factors should be taken into account synthetically: capacitor
voltage rank, capacitor value, and current virtual value. Based
on considerations as above, the capacitor models
941C12P15K and 941C12P22K attract us mostly. And single
class capacitors or models combined capacitors are paralleled
together as our resonant capacitor (for example:
K P C 15 12 941 10 , K P C 22 12 941 7 , or combination of the
upper models).
IV. HF TRANSFORMER DESIGN
Due to the HF transformer is connected in series with the
resonant tank, so the primary winding of transformer has the
same virtual value of the current as the resonant inductor.
Another unique design requirement of the HF transformer
can be concluded by analyzing the operating principle which
is expounded is section II. The support voltage of HF
transformer secondary winding
o N
v v =
2
, so the input
voltage of primary winding:
DC
o
o N
V
N
v
u v < = =
1
(15)
Expression (15) has significant meanings during
transformer design process:
a) for a given output requirement, maximum input voltage
of the transformer is constant without considering variation of
the input DC source
DC
V .
b) for the reason of a lower input voltage, the number of
winding turns is reduced, consequently, the parasitical
parameter of transformer (leakage inductance, winding
resistance, and parasitical capacitor) is lessened too. Also the
voltage overshoot which is caused by the leakage inductance
of transformer would be decreased remarkably.
Knowing the above factors, the design specification of HF
transformer (such as the input voltage, current value, power
capability and working frequency etc) is entire. The specific
values are presented below:
KHz f
s
50 = ; KW P
cap
1 = ; V V
DC
5 48 = ;
Primary winding: A I
RMS
70 = ;
Secondary winding: V v
out
310
max
= ;
Turn ratio calculation: taking into account the minimum
input DC voltage
min DC
V , so turn ratio is
2 . 7
min
max
= =
DC
out
V
v
N (16)
And considering the equivalent circle resistance which
include on-state resistance of the switches, winding resistance
of inductor and transformer, the turn ratio should substitute
8 = N for 2 . 7 = N , so the input voltage of primary winding
is:
N
v
u v
out
o N
max
max max 1
= = (17)
Magnetic core selection:
s m k tr
cap
w e
f B p J k
P
A A
6
10
(18)
Where:
tr
is the transformer efficiency;
cap
P is the transformer power capability;
k is the waveform factor ( 4 = k for rectangle waveform
or 44 . 4 = k for sine wave);
J is the current density in windings;
k
p is the packing factor of framework;
m
B is the maximal magnetic flux density;
s
f is the operational frequency;
IAS 2005 1479 0-7803-9208-6/05/$20.00 2005 IEEE
w
A is the window area of framework;
e
A is the effective center-pole area of core;
Utilizing (18) and a view of the framework window is big
enough for windings, the former magnetic core type
EE55/28/25 is selected for the HF transformer.
Number of winding turns:
8 max 1
10
1
=
e m s
N
p
A B f k
v
N (19)
Intercepting the integer of outcome (19), 2 =
p
N , so the
number of secondary winding turns is
p s
N N N = (20)
Winding conductor selection: considering the huge virtual
current value and the skin effect synthetically, the copper foil
which is 0.3mm thick satisfies our requirement exactly for the
primary winding. And single strand litz-wire which has the
same specification as used in resonant inductor winding is
used for the secondary winding. Also the current density of
transformer windings is same as inductor winding.
V. EXPERIMENTAL RESULT
Utilizing the aforementioned fabricated components, a
prototype is constructed for this practical application. The
design procedure is validated by the experimental results. A
series of compares which are presented during design process
are given.
(a) Resonant current of large circle
CH1: 40A/div
(b) Expandedness of the highest point
Fig.8. Resonant current and the magnification of the highest point
Fig.8 is the experimental results which correspond to Fig.4.
Contrasting these plots, a good match can be deduced. The
results also affirm that the resonant tank and HF transformer
design basic is correct.
Fig.9 shows the voltage waveform of HF transformer
primary winding and system output. (a) is corresponding to
(15); and (b) validates (17). There is a well-accordance
between analysis and experimental results, and this unique
character is used to minimize the parasitical parameters of HF
transformer.
(a) Voltage of primary winding and output in large circle
CH1: 20V/div; CH2: 100V/div
(b) Expandedness of the highest point
Fig.9. Voltage of primary winding and relevant output
Fig.10 shows the temperature rising of resonant inductor
core, the test conditions are: surrounding temperature is 24
o
C,
and power capability is 1KW. From the plot, core temperature
is steady at 70
o
C after 50 minutes. As pictured in Fig.5, the
core loss is reduced by its temperature rising. And temperature
rising is maximized based on the consideration of surrounding
temperature variation.
0
10
20
30
40
50
60
70
80
0 5 10 15 20 25 30 35 40 45 50
Time
T
e
m
p
e
r
a
t
u
r
e
Fig.10. Core temperature rising of resonant inductor
IAS 2005 1480 0-7803-9208-6/05/$20.00 2005 IEEE
Table III presents the different copper losses among three
kinds of conductor. The losses are estimated in the proportion
of total power consumption presumably. For copper foil and
solid round wire cases, the skin effect and proximity effect
have significant influence by fringing magnetic field
especially in large current case. Analyzing the data of
Litz-wire, copper loss has a linear relation with virtual current.
It means the ac resistance of inductor winding is affected by
skin effect and proximity effect punily.
TABLE III. COPPER LOSSES AMONG THREE CONDUCTORS
Copper foil Solid round wire Litz-wire
IRMS (A) Loss (W) IRMS (A) Loss (W) IRMS (A) Loss (W)
34.0 23.8 34.0 23.9 38.0 19.0
44.0 28.8 45.0 30.5 40.2 20.1
46.0 29.7 51.0 33.4 43.0 20.8
49.0 32.0 58.0 39.3 45.6 21.8
58.0 38.8 47.8 23.8
50.0 24.6
Fig.11 shows the sum of copper losses and core losses of
center-column air-gapped and dual-air-gapped inductors
which are tested on a series resonant DC/DC converter
prototype. And it is analyzed in section II as a demonstration.
This mainly validates which one has a more excellent
performance under a constant value of
max
B within a
switching period. As a contrast, in [10], the total losses of
optimum designed inductor are 55W at rated current
A I
rms
20 = . There is an obvious distinction between two
fabricated inductors that dual-air-gapped inductor has a lower
losses especially in large current case. It can be deduced that a
multi-air-gapped inductor would behave a well performance
though the air-gap is difficult to distribute symmetrically.
Comparing with 55W at 20A in [10], an air-gapped soft ferrite
magnetic core is more conformable than iron powder toriodal
core for this current rank.
0
5
10
15
20
25
30
35
0 10 20 30 40
Irms (A)
T
o
t
a
l
L
o
s
s
e
s
(
W
)
Dual air-gapped
Center-column air-gapped
Fig.11. Inductor total losses versus
rms
I
89.00%
89.20%
89.40%
89.60%
89.80%
90.00%
90.20%
90.40%
90.60%
90.80%
91.00%
503.7 669.1 749.2 833.6 969.7
Power capability
E
f
f
i
c
i
e
n
c
y
Fig.12. System efficiency versus power capability
Fig.12 shows the efficiency curve of a fabricated prototype
which is composed of the optimal components based on the
design procedure above. Beyond the design desire, the
prototype efficiency is above 90% within large-scale of load
condition.
(a) A photograph of the fabricated prototype
CH1: 100V/div; CH2: 10A/div
(b) System output
Fig.13. Fabricated prototype and its output
Fig.13 gives a photograph of the fabricated prototype and
its output. The system output has a low Total Harmonic
Distortion (THD). For ohmic load as show in fig.13:
% 715 . 0 =
Ohmic
THD . Under inductive load and no load:
% 837 . 0 =
Inductive
THD , and % 050 . 1 =
no
THD .
VI. CONCLUSION
In this paper, an industrial design procedure has been
advanced, which is mainly about the resonant tank and
transformer design in the series-resonant converter. The
design requirement of a practical application is presents via
the simulation, and the validity of the design procedure has
been proved by the experimental results. According to the
results among different designs which are used frequently
nowadays, an optimal choice is produced. Utilizing this choice,
a prototype is fabricated and it has an excellent overall
performance.
ACKNOWLEDGMENT
This work was supported by National Natural Science
IAS 2005 1481 0-7803-9208-6/05/$20.00 2005 IEEE
Foundation of China NO.50237020. Thanks Mao XK for his
support in winding design of the resonant inductor.
REFERENCES
[1] Yong-Ho Chung, Bong-Soo Shin, and Gyu-Hyeong Cho, Bilateral Series
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[2] Jin sheng Wei, Muneaki Ishida, and Takamasa Hori, Novel Real Time
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[3] M. Bartoli, A. Reatti, and M.K. Kazimierczuk, Minimum copper and core
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[10] K.W.E. Cheng, and P.D. Evans, Optimization of high frequency
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[14] Capacitors of CORNELL DUBILIER CDE Capacitor Products Data
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