Marzec, Todd
(2024)
High Frequency Toroidal Inductor Design for High Power Applications using Multi-Objective Optimization Considering AC Winding Losses and Parasitics.
Master's Thesis, University of Pittsburgh.
(Unpublished)
Abstract
Inductors are energy storage devices that serve as key components in power conversion technology. They often contribute the most to the overall size, weight and cost of power electronic circuits. The advent of wide-bandgap (WBG) semiconductor devices, and the promise of ultra-WBG, has led to high frequency (HF) operation of switching converters at higher operating voltage and currents. Now, an important limiting factor for HF and very-high frequency (VHF) power electronics are the passive magnetic components. In the kHz-MHz range, there are opportunities for increased power density and size reduction of inductors and transformers. However, additional sources of loss (skin effect, proximity effect, etc.,) in magnetic components interfacing to these WBG semiconductors are introduced due to high-frequency electromagnetic phenomena. These losses originate from the non-ideal magnetic core and the conductive winding. Aside from losses, parasitic (capacitive) effects become present and non-negligible at high frequency, as well. Inductor design with these phenomena in mind is supremely important to ensure safe and efficient operation in the upper kHz range and even into the 10s and 100s of MHz. Finite element analysis can capture these effects to a high degree of accuracy but require extensive computation time precluding application in robust optimization and design schemes. Therefore, analytical/closed-form equations are preferred for multi-objective optimization techniques where many designs need to be evaluated quickly. There exist several well-documented analytical models for winding loss and parasitic capacitance in literature that can evaluate multiple designs with minimal computation cost. In this thesis, popular models are reviewed, investigated, and expanded on in context of toroidal inductor designs using various winding geometries and core sizes. The contributions of this work are as follows: 1) analysis of existing winding loss models and demonstration of accuracy at high frequency as they pertain to toroidal inductors, 2) make necessary adjustments/improvements to the models to facilitate the best performance while maintaining low computation cost, 3) integration into a genetic optimization-based design algorithm for demonstration of inductor design trends when AC winding losses are included. Furthermore, 4) Litz wire’s role in high frequency magnetics is discussed and a novel approach to predicting winding loss for Litz wire toroidal inductors is laid out and benchmarked against another pre-existing model. Finally, 5) early work in parasitic capacitance modeling of toroidal inductors as well as other high frequency considerations are discussed.
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Details
| Item Type: |
University of Pittsburgh ETD
|
| Status: |
Unpublished |
| Creators/Authors: |
|
| ETD Committee: |
|
| Date: |
6 September 2024 |
| Date Type: |
Publication |
| Defense Date: |
14 May 2024 |
| Approval Date: |
6 September 2024 |
| Submission Date: |
30 April 2024 |
| Access Restriction: |
No restriction; Release the ETD for access worldwide immediately. |
| Number of Pages: |
70 |
| Institution: |
University of Pittsburgh |
| Schools and Programs: |
Swanson School of Engineering > Electrical and Computer Engineering |
| Degree: |
MS - Master of Science |
| Thesis Type: |
Master's Thesis |
| Refereed: |
Yes |
| Uncontrolled Keywords: |
Analytical, skin effect, proximity effect, toroidal, inductor, winding loss, parasitic capacitance, high power. |
| Date Deposited: |
06 Sep 2024 19:54 |
| Last Modified: |
06 Sep 2024 19:54 |
| URI: |
http://d-scholarship.pitt.edu/id/eprint/46374 |
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