CN113314310A - Magnetic integrated inductor and manufacturing method thereof, and double-path interleaved PFC circuit - Google Patents

Magnetic integrated inductor and manufacturing method thereof, and double-path interleaved PFC circuit Download PDF

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CN113314310A
CN113314310A CN202110466670.2A CN202110466670A CN113314310A CN 113314310 A CN113314310 A CN 113314310A CN 202110466670 A CN202110466670 A CN 202110466670A CN 113314310 A CN113314310 A CN 113314310A
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inductor
core
magnetic core
magnetic
coil
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梁栋
杨帆
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Gree Electric Appliances Inc of Zhuhai
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Gree Electric Appliances Inc of Zhuhai
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/24—Magnetic cores
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/28—Coils; Windings; Conductive connections
    • H01F27/30—Fastening or clamping coils, windings, or parts thereof together; Fastening or mounting coils or windings on core, casing, or other support
    • H01F27/306—Fastening or mounting coils or windings on core, casing or other support
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F37/00—Fixed inductances not covered by group H01F17/00
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
    • H02M1/00—Details of apparatus for conversion
    • H02M1/42—Circuits or arrangements for compensating for or adjusting power factor in converters or inverters
    • H02M1/4208—Arrangements for improving power factor of AC input
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02B—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS
    • Y02B70/00—Technologies for an efficient end-user side electric power management and consumption
    • Y02B70/10—Technologies improving the efficiency by using switched-mode power supplies [SMPS], i.e. efficient power electronics conversion e.g. power factor correction or reduction of losses in power supplies or efficient standby modes

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  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Coils Or Transformers For Communication (AREA)

Abstract

The invention discloses a magnetic integrated inductor and a manufacturing method thereof, and a double-path interleaved PFC circuit, wherein the magnetic integrated inductor comprises: a first inductor and a second inductor; the first inductor and the second inductor are integrally arranged to form a magnetic integrated coupling inductor; the first inductor includes: a first magnetic core and a first coil; the second inductor comprising: a second magnetic core and a second coil; wherein the first coil is wound around the first magnetic core to form the first inductor; the second coil is wound on the second magnetic core to form the second inductor; the first magnetic core and the second magnetic core are integrally arranged on one magnetic core structure. According to the scheme, two independent inductors of the two PFC circuits are integrated into one coupling inductor, so that the inductance volumes of the two PFC circuits can be reduced.

Description

Magnetic integrated inductor and manufacturing method thereof, and double-path interleaved PFC circuit
Technical Field
The invention belongs to the technical field of electronic circuits, and particularly relates to a magnetic integrated inductor and a manufacturing method thereof, and a two-way interleaved PFC circuit, in particular to a magnetic integrated inductor for a two-way interleaved PFC circuit and a manufacturing method thereof, and a two-way interleaved PFC circuit with the magnetic integrated inductor.
Background
The two-way interleaved parallel PFC (power factor correction) circuit is characterized in that the two PFC circuits are connected in parallel at an interval of 180 degrees. In a related scheme, two independent inductors are used in the two PFC circuits, and the volume of the inductors occupies a large proportion in the circuit, so that the circuit volume is increased.
The above is only for the purpose of assisting understanding of the technical aspects of the present invention, and does not represent an admission that the above is prior art.
Disclosure of Invention
The invention aims to provide a magnetic integrated inductor, a manufacturing method thereof and a two-way interleaved PFC circuit, so as to solve the problem that two independent inductors are used in the two-way PFC circuit, so that the inductance volume of the two-way PFC circuit is large, and achieve the effect of reducing the inductance volume of the two-way PFC circuit by integrating the two independent inductors of the two-way PFC circuit into a coupling inductor.
The present invention provides a magnetic integrated inductor, comprising: a first inductor and a second inductor; the first inductor and the second inductor are integrally arranged to form a magnetic integrated coupling inductor.
In some embodiments, the first inductor comprises: a first magnetic core and a first coil; the second inductor comprising: a second magnetic core and a second coil; wherein the first coil is wound around the first magnetic core to form the first inductor; the second coil is wound on the second magnetic core to form the second inductor; the first magnetic core and the second magnetic core are integrally arranged on one magnetic core structure.
In some embodiments, wherein the first magnetic core is shaped as an E-shape; the first coil is formed by winding the same-phase winding on different magnetic core columns of the first magnetic core; the shape of the second magnetic core is E-shaped or I-shaped; under the condition that the shape of the second magnetic core is E-shaped, the second coil is formed by winding the same-phase winding on different magnetic core columns of the second magnetic core; and under the condition that the shape of the second magnetic core is I-shaped, the second coil is formed by winding the same-phase winding on different magnetic core columns of the first magnetic core, and no winding is wound on the magnetic core column of the second magnetic core.
In some embodiments, the coupling direction of the first coil when wound on the first core and the coupling direction of the second coil when wound on the second core are a forward coupling direction or a reverse coupling direction.
In some embodiments, in a case where the first core is shaped like an E, of the first core and the first coil, the first coil is wound on a leg of the first core, and no winding is wound on a center leg of the first core; in the case where the second core is E-shaped, the second coil is wound around the side legs of the second core, and no winding is wound around the center leg of the second core, out of the second core and the second coil; in the case where the second core is of the I-type shape, of the first core and the second core, the second coil is wound around the side legs of the first core, and no winding is wound around the center leg of the first core; or, in the case that the second magnetic core is in an I-shape, the second coil is formed by winding the same-phase winding around a different core leg of the first magnetic core, and no winding is wound around the core leg of the second magnetic core, in the second magnetic core and the second coil.
In some embodiments, the number of windings of each phase winding on different core legs is different in the first coil and the second coil.
In some embodiments, the air gap lengths of all legs are the same in different legs of the first magnetic core and different legs of the second magnetic core.
In accordance with another aspect of the present invention, there is provided a dual-path interleaved PFC circuit, including: the magnetically integrated inductor described above.
Matching with the two-way interleaved PFC circuit, a further aspect of the present invention provides a method for manufacturing a magnetic integrated inductor, comprising: determining a first inductance parameter of the first inductor and a second inductance parameter of the second inductor according to a set specification; manufacturing the first inductor according to a first inductance parameter of the first inductor; manufacturing the second inductor according to a second inductance parameter of the second inductor; integrally disposing a first core of the first inductor and a second core of the second inductor on a core structure to form the magnetically integrated inductor.
In some embodiments, an inductance parameter of the first inductance parameter and the second inductance parameter comprises: at least one of a coupling factor, a self-inductance, a winding wire diameter, a core size, a number of winding turns, a core window area, and an air gap length.
Therefore, according to the scheme of the invention, two independent inductors are integrated into one coupled inductor, and the coupled inductor is adopted to replace the two independent inductors of the two PFC circuits; therefore, two independent inductors of the two PFC circuits are integrated into one coupling inductor, so that the inductance volume of the two PFC circuits can be reduced.
Additional features and advantages of the invention will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention.
The technical solution of the present invention is further described in detail by the accompanying drawings and embodiments.
Drawings
FIG. 1 is a schematic structural diagram of an embodiment of a magnetically integrated inductor of the present invention;
FIG. 2 is a schematic diagram of an embodiment of a magnetically integrated inductor; wherein, (a) is a structural schematic diagram of the magnetic integrated inductor when the EE type magnetic core is coupled in the forward direction, (b) is a structural schematic diagram of the magnetic integrated inductor when the EE type magnetic core is coupled in the reverse direction, (c) is a structural schematic diagram of the magnetic integrated inductor when the EI type magnetic core is coupled in the forward direction, and (d) is a structural schematic diagram of the magnetic integrated inductor when the EI type magnetic core is coupled in the reverse direction;
FIG. 3 is a schematic diagram of a magnetic circuit structure of an embodiment of a magnetically integrated inductor;
FIG. 4 is a schematic view of the magnetic flux waveform of the center leg and the side legs of the forward coupled magnetically integrated inductor; wherein, (a) is a magnetic flux waveform schematic diagram of the middle post and the side post when the duty ratio is more than 0 and less than or equal to 0.5, and (b) is a magnetic flux waveform schematic diagram of the middle post and the side post when the duty ratio is more than 0.5 and less than 1;
FIG. 5 is a schematic view of the magnetic flux waveform of the center leg and the side legs of the counter-coupled magnetically integrated inductor; wherein, (a) is a magnetic flux waveform schematic diagram of the middle post and the side post when the duty ratio is more than 0 and less than or equal to 0.5, and (b) is a magnetic flux waveform schematic diagram of the middle post and the side post when the duty ratio is more than 0.5 and less than 1;
FIG. 6 is a schematic diagram illustrating a fabrication process of an embodiment of a magnetically integrated inductor;
FIG. 7 is a flow chart illustrating a method of fabricating a magnetically integrated inductor according to an embodiment of the present invention;
fig. 8 is a schematic structural diagram of a first magnetic core and a second magnetic core in the magnetically integrated inductor of the present invention.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the technical solutions of the present invention will be clearly and completely described below with reference to the specific embodiments of the present invention and the accompanying drawings. It is to be understood that the described embodiments are merely exemplary of the invention, and not restrictive of the full scope of the invention. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
According to an embodiment of the present invention, a magnetically integrated inductor is provided. Referring to fig. 1, a schematic diagram of an embodiment of the apparatus of the present invention is shown. The magnetically integrated inductor may include: a first inductor and a second inductor. The first inductor and the second inductor are integrally arranged to form a magnetic integrated coupling inductor.
Specifically, the problem of large size of the inductor is solved by integrating two independent inductors into one coupled inductor (i.e. magnetic integrated coupled inductor), thereby reducing the size of the inductor.
In some embodiments, the first inductor comprises: a first magnetic core and a first coil. The second inductor comprising: a second magnetic core and a second coil.
Wherein the first coil is wound around the first magnetic core to form the first inductor. The second coil is wound on the second magnetic core to form the second inductor. The first magnetic core and the second magnetic core are integrally arranged on one magnetic core structure.
Therefore, the two magnetic elements are integrated on the magnetic core structure to form the magnetic integrated inductor for the double-path staggered PFC circuit, the voltage and current relation of each magnetic element in the circuit topology and the magnetic flux and magnetomotive force relation in the magnetic circuit topology are fully utilized, the integration of the two magnetic elements is realized, the size of a magnetic device is reduced, the input and inductive current ripples are improved, the transient response speed of the power supply is improved, and therefore the loss can be reduced, the power density is improved, and the output stability of the power supply is ensured.
In some embodiments, the first magnetic core is E-shaped. The first coil is formed by winding the same-phase winding on different magnetic core columns of the first magnetic core.
The second magnetic core is E-shaped or I-shaped. And when the second magnetic core is in an E shape, the second coil is formed by winding the same-phase winding on different magnetic core columns of the second magnetic core. And under the condition that the shape of the second magnetic core is I-shaped, the second coil is formed by winding the same-phase winding on different magnetic core columns of the first magnetic core, and no winding is wound on the magnetic core column of the second magnetic core.
Therefore, the same phase winding is wound on different magnetic core columns, the coupling factor of forward coupling or reverse coupling can be improved, so that the input current ripple or the inductive current ripple is further reduced, namely the input current ripple or the inductive current ripple is further reduced in the forward coupling process or the reverse coupling process, the problem of large input current ripple or inductive current ripple can be solved, and the circuit efficiency of the two PFC circuits is improved.
In some embodiments, the coupling direction of the first coil when wound on the first core and the coupling direction of the second coil when wound on the second core are a forward coupling direction or a reverse coupling direction.
Specifically, the magnetic core adopts EE or EI and other similar shapes, the material can be soft magnetic ferrite material, and the air gap lengths of the three magnetic core columns are the same. EE is a magnetic circuit formed by two E-shaped magnetic cores, and EI is a magnetic circuit formed by the E-shaped magnetic core and the I-shaped magnetic core. The winding method of the two-phase winding can be divided into a forward coupling winding method or a reverse coupling winding method.
In some embodiments, in a case where the first core is shaped like an E, the first coil is wound on the leg of the first core among the first core and the first coil, and no winding is wound on the center leg of the first core.
In the case where the second core is E-shaped, the second coil is wound around the side legs of the second core, and no winding is wound around the center leg of the second core, of the second core and the second coil.
In the case where the second core is of the I-type shape, of the first core and the second core, the second coil is wound around the side legs of the first core, and no winding is wound around the center leg of the first core; or, in the case that the second magnetic core is in an I-shape, the second coil is formed by winding the same-phase winding around a different core leg of the first magnetic core, and no winding is wound around the core leg of the second magnetic core, in the second magnetic core and the second coil.
In some embodiments, the number of windings of each phase winding on different core legs is different in the first coil and the second coil.
Specifically, the winding of each phase is wound on the two side legs of the core, the total number of turns of the winding of each phase is N + N '(assuming that N is greater than N'), and no winding is wound on the center leg of the core. Thus, the coupling factor of the magnetically integrated inductor of this configuration may be greater than or equal to one third.
In some embodiments, the air gap lengths of all legs are the same in different legs of the first magnetic core and different legs of the second magnetic core. The magnetic core is unnecessary to be cut by enabling the air gap lengths of the magnetic core columns to be the same, and therefore the magnetic integrated inductor is simpler and more convenient to manufacture.
Through a large number of tests, the technical scheme of the invention is adopted, two independent inductors are integrated into a coupling inductor, and the coupling inductor is adopted to replace the two independent inductors of two PFC circuits. Therefore, two independent inductors of the two PFC circuits are integrated into one coupling inductor, so that the inductance volume of the two PFC circuits can be reduced.
According to an embodiment of the invention, a two-way interleaved PFC circuit corresponding to the magnetically integrated inductor is also provided. The two-way interleaved PFC circuit may include: the magnetically integrated inductor described above.
In the two-way interleaved parallel PFC circuit, the two PFC circuits are connected in parallel at an interval of 180 degrees, and the input current of the two PFC circuits is the sum of the inductive currents of the two PFC circuits. Because the currents of the inductors are not in phase, they cancel each other out and reduce input current ripple, thereby improving efficiency and stability.
In the related scheme, when the inductors of the two PFC circuits are integrated, the two magnetic cores need to be cut according to different requirements, the operation process is complex, and the application range of the cut magnetic cores is limited.
For example: in the related scheme, a reverse coupling mode is adopted, and the current reduction speed in the inductor is improved, so that the current ripple of the inductance coil is smaller, namely the effective value and the peak value of the inductance current are smaller. The scheme of the invention adopts two modes of reverse coupling and forward coupling, wherein the reverse coupling can improve the inductive current ripple, the forward coupling can improve the input current ripple, and a proper coupling mode can be adopted according to specific requirements.
In the related scheme, the adopted magnetic core is a specially-made magnetic core made of ferrite. According to the scheme of the invention, a special magnetic core is not adopted, but a general E-type or I-type magnetic core is adopted, as shown in fig. 8, the bottom plate is in a rectangular structure, two side columns are rectangular columns or approximate rectangular columns, and one central column is a rectangular column, an elliptic column or a circular column, so that the general magnetic core structure is adopted, and the purchase cost is saved.
In the related scheme, two coils are respectively wound on two side columns to form two inductance coils. A plurality of air gaps are arranged on the side columns, and a plurality of air gaps are arranged on the central column. The sum of the lengths of the first air gaps is smaller than the sum of the lengths of the second air gaps, namely the total air gap length of the side columns is smaller than the total air gap length of the central column, and at this moment, the single-side inductance coil cannot be saturated. Because the magnetic core is specially made, the length of the central column is smaller than that of the side columns in the manufacturing process, so that the magnetic core does not need to be cut. However, if a commercially available magnetic core is used, the magnetic core needs to be cut again so that the total air gap length of the side columns is smaller than that of the central column. The scheme of the invention also has two inductance coils, but each inductance coil is wound on two side columns, rather than one inductance coil is wound on only one side column. The total air gap length of the side columns is equal to that of the central column, so that the air gap can be formed only by adding an air gap gasket without cutting the magnetic core, and the air gap gasket is made of non-magnetic and non-conductive insulating materials.
In addition, in the related art, the manufacturing method and steps are not given.
In some embodiments, the present invention provides a magnetic integrated inductor for a two-way interleaved PFC circuit, in which two independent inductors are integrated into one coupled inductor (i.e., a magnetic integrated coupled inductor), so as to reduce the size of the inductor and solve the problem of large size of the inductor.
Furthermore, according to the scheme of the invention, the same phase of winding is wound on different magnetic core columns, so that the coupling factor of forward coupling or reverse coupling can be improved, and the input current ripple or the inductive current ripple is further reduced, namely the input current ripple or the inductive current ripple is further reduced during forward coupling or during reverse coupling, the problem of large input current ripple or inductive current ripple can be solved, and the circuit efficiency of two PFC circuits is improved; meanwhile, the air gap lengths of all the magnetic core columns are the same, and the magnetic cores do not need to be cut, so that the magnetic integrated inductor is simpler and more convenient to manufacture.
Thus, according to the scheme of the invention, two magnetic elements (such as a first magnetic core and a second magnetic core) are integrated on a magnetic core structure (such as a magnetic core formed by integrating the first magnetic core and the second magnetic core) to form the magnetic integrated inductor for the double-path interleaved PFC circuit, the voltage and current relationship of each magnetic element in a circuit topology and the magnetic flux and magnetomotive force relationship in a magnetic circuit topology are fully utilized, the integration of the two magnetic elements is realized, the volume of a magnetic device is reduced, the input and inductive current ripples are improved, the transient response speed of a power supply is increased, and therefore, the loss can be reduced, the power density is increased, and the output stability of the power supply is ensured.
The self-inductance and the coupling factor have a corresponding relation with voltage and current in a circuit, and also have a corresponding relation with magnetic flux and magnetomotive force in a magnetic circuit. Therefore, the magnetic circuit and the electric circuit can be connected through the self-inductance and the coupling factor, so that the design and integration of the magnetic element can be realized according to the characteristics of the electric circuit.
The following describes an exemplary implementation process of the scheme of the present invention with reference to the examples shown in fig. 2 to fig. 6.
FIG. 2 is a schematic diagram of an embodiment of a magnetically integrated inductor; the structure of the magnetic integrated inductor is schematically illustrated in the following steps, wherein (a) is a structural schematic diagram of the magnetic integrated inductor when the EE type magnetic core is coupled in the forward direction, (b) is a structural schematic diagram of the magnetic integrated inductor when the EE type magnetic core is coupled in the reverse direction, (c) is a structural schematic diagram of the magnetic integrated inductor when the EI type magnetic core is coupled in the forward direction, and (d) is a structural schematic diagram of the magnetic integrated inductor when the EI type magnetic core is coupled in the reverse direction. As shown in fig. 2, the magnetic core adopts EE or EI and the like, the material can be soft magnetic ferrite material, and the air gap lengths of the three magnetic core columns are the same. EE is a magnetic circuit formed by two E-shaped magnetic cores, and EI is a magnetic circuit formed by the E-shaped magnetic core and the I-shaped magnetic core. The winding method of the two-phase winding can be classified into an EE-type core forward-coupling winding method shown in fig. 2 (a), an EE-type core reverse-coupling winding method shown in fig. 2 (b), an EI-type core forward-coupling winding method shown in fig. 2 (c), and an EI-type core reverse-coupling winding method shown in fig. 2 (d).
In the example shown in fig. 2, the winding of each phase is wound on both core legs, the total number of turns of the winding of each phase is N + N '(assuming N is greater than N'), and no winding is wound on the core legs. Thus, the coupling factor of the magnetically integrated inductor of this configuration may be greater than or equal to one third.
Fig. 3 is a schematic diagram of a magnetic circuit structure of an embodiment of the magnetically integrated inductor. As shown in fig. 3, the magnetic circuit corresponding to the magnetic integrated inductor includes: magnetic resistance Rc and two magnetic resistances Ro, magnetomotive force NiL1Magnetomotive force N' iL1Magnetomotive force rho N' iL2And magnetomotive force ρ NiL2. Magnetomotive force NiL1Connected to the magnetomotive force N' iL1And a magnetomotive force rho N' i connected to the negative electrode via a magnetic resistance RcL2Negative electrode and magnetomotive force ρ NiL2The positive electrode of (1). ρ of 1 represents forward coupling and ρ of-1 represents reverse coupling. Magnetomotive force NiL1Is connected to the magnetomotive force rho N' i after a magnetic resistance RoL2The positive electrode of (1). Magnetomotive force N' iL1Is connected to the magnetomotive force ρ Ni after passing through another reluctance RoL2The negative electrode of (1). Phi01、Φ02、ΦcIs the magnetic flux.
FIG. 4 is a schematic view of the magnetic flux waveform of the center leg and the side legs of the forward coupled magnetically integrated inductor; wherein, (a) is a magnetic flux waveform diagram of the center pole and the side pole when the duty ratio is more than 0 and less than or equal to 0.5, and (b) is a magnetic flux waveform diagram of the center pole and the side pole when the duty ratio is more than 0.5 and less than 1. FIG. 5 is a schematic view of the magnetic flux waveform of the center leg and the side legs of the counter-coupled magnetically integrated inductor; wherein, (a) is a magnetic flux waveform schematic diagram of the center pillar and the side pillar when the duty ratio is more than 0 and less than or equal to 0.5, and (b) is a magnetic flux waveform schematic diagram of the center pillar and the side pillar when the duty ratio is more than 0.5 and less than 1. In fig. 4 and 5, Ts is the switching period of the two-way interleaved PFC circuit, Q1、Q2Two switches in the two-path interleaved PFC circuit, D is a duty ratio.
By analyzing the magnetic circuit corresponding to the magnetic integrated inductor shown in fig. 3, the magnetic flux waveforms of the magnetic integrated inductor shown in fig. 4 and 5 can be obtained, and these waveforms indicate that the magnetic integrated inductor has the maximum magnetic induction intensity of the magnetic core side pillar no matter in forward coupling or reverse coupling, so the magnetic core side pillar should be designed based on the magnetic induction intensity of the magnetic core side pillar during design, and the magnetic core side pillar is ensured to be unsaturated.
In the aspect of the magnetic integrated structure, since the integrated magnetic element is designed for a specific circuit, the magnetic integrated structure has no fixed form, and firstly, what kind of magnetic integrated structure is adopted according to the specific circuit topology of the application so as to realize the function of the specific circuit. Therefore, not only is the requirements of a particular circuit considered during design, but analysis of the integrated magnetic element after design is complete is also important. In addition, the integrated structure is selected by comprehensively considering the influence of the integrated structure on iron loss and current ripple so as to optimize the circuit performance, thereby selecting the best magnetic integrated structure from various magnetic integrated structure schemes.
For example: the existing magnetic integrated inductor in the related scheme is a non-coupling structure at first, namely a magnetic integrated non-coupling double inductor with two phases of inductance coils respectively wound on two different side columns, no air gap exists in a center column, and air gaps exist in two side columns. Considering that the coupled inductor can optimize the current ripple and improve the efficiency compared with the non-coupled inductor, some similar magnetically integrated coupled inductors have appeared later, i.e. the central pillar has an air gap, and the central pillar air gap is different from the two side pillar air gaps in length. However, if a general magnetic core is adopted, the magnetic core is inevitably cut, so that the operation process is complicated, and the application range of the cut magnetic core is limited. Therefore, the inventor of the present invention has conceived a method of winding the coil winding of each phase around different legs, respectively, in consideration of whether the effect of the magnetically integrated coupled inductor can be achieved without cutting the core, so that the air gaps of the legs can be made the same, and the air gaps can be formed by adding air gap spacers, and the magnetically integrated coupled inductor is also used. Then, specific circuits and magnetic integrated structures are analyzed to determine specific design methods, and the difficulty mainly lies in the determination of the magnetic integrated structures and the determination of the design methods.
In the scheme of the invention, a set of inductor design and manufacturing process shown in figure 6 is determined and a parameter calculation method is concluded through the analysis of a circuit and a magnetic circuit, so that the difficulty in selecting parameters such as the type of a magnetic core, the size of an air gap, the specification of a wire and the like is solved.
Fig. 6 is a schematic fabrication flow diagram of an embodiment of a magnetically integrated inductor. As shown in fig. 6, a process of manufacturing a magnetically integrated inductor includes:
and step 1, specification setting.
For example: the given parameters mainly include minimum input voltage, maximum input voltage, output voltage, maximum output power, efficiency, switching frequency, input current ripple and inductor current ripple range at minimum input voltage and full load, maximum magnetic flux density, maximum current density, and core window utilization.
And 2, determining the coupling factor and the self-inductance.
The coupling factor and self-inductance may be determined according to the input current ripple and inductor current ripple ranges required in the design specifications.
And step 3, determining the wire diameter of the winding. Cross section of winding AwIt can be determined that:
Aw≥ILrms/Jmax。
using calculated AwAn appropriate wire diameter can be selected from the winding selection table. Wherein, ILrmsIs an inductance current effective value; j. the design is a squaremaxIs the maximum current density.
And 4, determining the size of the magnetic core by an AP method. The selection is made using the AP method, the AP expression is as follows:
AP＝2×104(1+α)ILrms(φdc+Δφ)/JmaxKucm4。
where α is the scaling factor of the number of turns N and N', i.e.
Figure BDA0003044339470000091
φdcIs the side column DC magnetic flux, and Δ φ is the side column ripple magnetic flux, KuThe coefficient is used for the core window.
And 5, determining the number of turns of the winding. N may be represented by the formula N ═ phidc+Δφ)/(BmaxAeo) The calculation is performed, and N 'can be calculated using the expression N' ═ α N.
Wherein, BmaxMaximum flux density of side column, AeoThe cross-sectional area of the magnetic core side column.
Step 6, judging whether the area of the winding is suitable for the area of a magnetic core window, if so, executing step 7; otherwise, selecting a larger magnetic core and returning to the step 5. The following formula is utilized:
(N+N’)Aw≤KuWa。
if the above formula is not satisfied, a larger size core should be selected. Wherein, WaIs a window area of the magnetic core.
And 7, determining the length of the air gap.
Air gap length l without magnetic core reluctance and air gap magnetic field edge effectgCan be approximately expressed as:
lg＝(3N2+2NN’+3N’2)μoAeo/(4Ls)。
in the formula: mu.soIs magnetic permeability in vacuum, LsIs self-inductive.
In the scheme of the invention, in the aspect of magnetic integration design, because the integrated magnetic element has a different structure from a common discrete magnetic element, certain difficulty exists in the selection of parameters such as the type of a magnetic core, the size of an air gap, the specification of a wire and the like. In the related scheme, a general parameter calculation method is not available, and a designer generally determines a design scheme and a manufacturing process according to actual requirements.
Referring to the example shown in fig. 6, by selecting a large absolute value of the coupling factor to design the magnetic integrated inductor, the input current ripple can be made smaller when forward coupling is adopted, and the inductive current ripple can be made smaller when reverse coupling is adopted, and simultaneously, the air gap lengths of the three magnetic core columns are the same, so that the magnetic core can be prevented from being cut, the manufacturing process is simplified, and the working hours are reduced. The size of the magnetic core is selected by deducing an AP method (namely an area product method) calculation formula of the magnetic integrated inductor with the structure, so that the magnetic core can not be saturated when the circuit operates.
In summary, the solution of the present invention is to integrate the independent inductor into the magnetic integrated coupled inductor, rather than integrating the independent inductor into the magnetic integrated independent inductor. Compared with the independent inductor, the coupled inductor can make the input current ripple smaller when the forward coupling with large coupling factor is adopted, and can make the inductance current ripple smaller when the reverse coupling with large coupling factor is adopted, so that the circuit efficiency can be higher.
Since the processing and functions of the two-way interleaved PFC circuit of this embodiment substantially correspond to the embodiments, principles, and examples of the apparatus shown in fig. 1, reference may be made to the related descriptions in the foregoing embodiments without specific details in the description of this embodiment, and no further description is given here.
Through a large number of tests, the technical scheme of the invention is adopted, two independent inductors are integrated into one coupling inductor, and the coupling inductor is adopted to replace two independent inductors of two PFC circuits, so that the size of a magnetic device is reduced, input and inductive current ripples are improved, and the transient response speed of a power supply is increased.
According to an embodiment of the present invention, a method for manufacturing a magnetic integrated inductor corresponding to a two-way interleaved PFC circuit is also provided, as shown in fig. 7, which is a schematic flow chart of an embodiment of the method of the present invention. The manufacturing method of the magnetic integrated inductor can comprise the following steps: step S110 to step S130.
At step S110, a first inductance parameter of the first inductor and a second inductance parameter of the second inductor are determined according to the set specification.
At step S120, the first inductor is fabricated according to the first inductance parameter of the first inductor. And manufacturing the second inductor according to the second inductance parameter of the second inductor.
At step S130, a first magnetic core of the first inductor and a second magnetic core of the second inductor are integrally disposed on one magnetic core structure, forming the magnetically integrated inductor.
Specifically, by integrating the independent inductors as the magnetically integrated coupling inductors, the input current ripple can be made smaller when forward coupling with a large coupling factor is employed, and the inductor current ripple can be made smaller when reverse coupling with a large coupling factor is employed, so that the circuit efficiency can be made higher.
In some embodiments, an inductance parameter of the first inductance parameter and the second inductance parameter comprises: at least one of a coupling factor, a self-inductance, a winding wire diameter, a core size, a number of winding turns, a core window area, and an air gap length.
Specifically, through selecting big coupling factor absolute value to carry out magnetism integrated inductor design, can make the input current ripple become littleer when adopting forward coupling, and can make the inductive current ripple become littleer when adopting reverse coupling, the air gap length of three core limb is the same simultaneously, can avoid the magnetic core to be cut, simplifies the manufacturing process and reduces man-hour. The size of the magnetic core is selected by deducing an AP method (namely an area product method) calculation formula of the magnetic integrated inductor with the structure, so that the magnetic core can not be saturated when the circuit operates.
Since the processes and functions implemented by the method of this embodiment substantially correspond to the embodiments, principles and examples of the magnetic integrated inductor, reference may be made to the related descriptions in the foregoing embodiments without being detailed in the description of this embodiment.
Through a large number of tests, the technical scheme of the embodiment is adopted, two independent inductors are integrated into one coupling inductor, and the coupling inductor is adopted to replace the two independent inductors of two PFC circuits, so that the loss can be reduced, the power density is improved, and the output stability of the power supply is ensured.
In summary, it is readily understood by those skilled in the art that the advantageous modes described above can be freely combined and superimposed without conflict.
The above description is only an example of the present invention, and is not intended to limit the present invention, and it is obvious to those skilled in the art that various modifications and variations can be made in the present invention. Any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention should be included in the scope of the claims of the present invention.

Claims (9)

1. A magnetically integrated inductor, comprising: a first inductor and a second inductor; the first inductor and the second inductor are integrally arranged to form a magnetic integrated coupling inductor; the first inductor includes: a first magnetic core and a first coil; the second inductor comprising: a second magnetic core and a second coil; wherein the content of the first and second substances,
the first coil is wound on the first magnetic core to form the first inductor; the second coil is wound on the second magnetic core to form the second inductor; the first magnetic core and the second magnetic core are integrally arranged on one magnetic core structure.
2. The magnetically integrated inductor of claim 1, wherein,
the first magnetic core is E-shaped; the first coil is formed by winding the same-phase winding on different magnetic core columns of the first magnetic core;
the shape of the second magnetic core is E-shaped or I-shaped;
under the condition that the shape of the second magnetic core is E-shaped, the second coil is formed by winding the same-phase winding on different magnetic core columns of the second magnetic core;
and under the condition that the shape of the second magnetic core is I-shaped, the second coil is formed by winding the same-phase winding on different magnetic core columns of the first magnetic core, and no winding is wound on the magnetic core column of the second magnetic core.
3. The magnetically integrated inductor of claim 2, wherein the coupling direction of the first coil when wound on the first core and the coupling direction of the second coil when wound on the second core are a forward coupling direction or a reverse coupling direction.
4. The magnetically integrated inductor according to claim 2, wherein in the case where the first core is E-shaped, of the first core and the first coil, the first coil is wound around the leg of the first core, and no winding is wound around the center leg of the first core;
in the case where the second core is E-shaped, the second coil is wound around the side legs of the second core, and no winding is wound around the center leg of the second core, out of the second core and the second coil;
in the case where the second core is of the I-type shape, of the first core and the second core, the second coil is wound around the side legs of the first core, and no winding is wound around the center leg of the first core; or, in the case that the second magnetic core is in an I-shape, the second coil is formed by winding the same-phase winding around a different core leg of the first magnetic core, and no winding is wound around the core leg of the second magnetic core, in the second magnetic core and the second coil.
5. The magnetically integrated inductor of claim 2, wherein the number of turns of each phase winding on different legs in the first and second coils is different.
6. The magnetically integrated inductor of claim 2, wherein the air gap lengths of all legs are the same in different legs of the first magnetic core and different legs of the second magnetic core.
7. A two-way interleaved PFC circuit comprising: a magnetically integrated inductor as claimed in any one of claims 1 to 6.
8. A method of fabricating a magnetically integrated inductor according to any of claims 1 to 6, comprising:
determining a first inductance parameter of the first inductor and a second inductance parameter of the second inductor according to a set specification;
manufacturing the first inductor according to a first inductance parameter of the first inductor; manufacturing the second inductor according to a second inductance parameter of the second inductor;
integrally disposing a first core of the first inductor and a second core of the second inductor on a core structure to form the magnetically integrated inductor.
9. The method of claim 8, wherein an inductance parameter of the first inductance parameter and the second inductance parameter comprises: at least one of a coupling factor, a self-inductance, a winding wire diameter, a core size, a number of winding turns, a core window area, and an air gap length.
CN202110466670.2A 2021-04-28 2021-04-28 Magnetic integrated inductor and manufacturing method thereof, and double-path interleaved PFC circuit Pending CN113314310A (en)

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