EP2927918A2 - Inductance et noyau inducteur - Google Patents

Inductance et noyau inducteur Download PDF

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Publication number
EP2927918A2
EP2927918A2 EP15160023.6A EP15160023A EP2927918A2 EP 2927918 A2 EP2927918 A2 EP 2927918A2 EP 15160023 A EP15160023 A EP 15160023A EP 2927918 A2 EP2927918 A2 EP 2927918A2
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EP
European Patent Office
Prior art keywords
core
leg
coils
outer legs
shaped
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
EP15160023.6A
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German (de)
English (en)
Other versions
EP2927918B1 (fr
EP2927918A3 (fr
Inventor
Johann Winkler
Robert Ludwig
Herbert Jungwirth
Ernst Holzinger
Iyad Kebaisy
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Sumida Components and Modules GmbH
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Sumida Components and Modules GmbH
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Publication date
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Publication of EP2927918A2 publication Critical patent/EP2927918A2/fr
Publication of EP2927918A3 publication Critical patent/EP2927918A3/fr
Application granted granted Critical
Publication of EP2927918B1 publication Critical patent/EP2927918B1/fr
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Anticipated expiration legal-status Critical

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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
    • 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
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/28—Coils; Windings; Conductive connections

Definitions

  • the present invention relates to a choke with a core and a core optimized for use with boost converter or buck converter circuits or power factor correction (PFC) in interleaved configuration. Furthermore, the present invention relates to an optimized double coil core for interleaved applications in boost converter or buck converter circuits or power correction devices (power factor compensation, PFC).
  • PFC power factor compensation
  • throttle is understood below an arrangement of one or more coils sitting on a common core.
  • a boost converter or step-down converter is understood to mean a circuit which can set a DC voltage higher or lower. Step-up and step-down converters operate on similar principles to power correction filters and sometimes use the same components.
  • Power factor is the ratio of the amount of active power to the amount of apparent power. A value less than 1 means that the apparent power sourced from the grid is greater than the active power, so that the grid is additionally burdened by reactive power which must be provided and transported, and which must in part flow back across the grids , As a result, higher losses occur in the network and the network must be dimensioned larger than is actually necessary.
  • Power factor correction filters ensure that the power factor is as close as possible to 1, that is, only pure active power is taken from the supply network. In the case of an active power factor correction (PFC), the absorbed current is readjusted to the time course of the sinusoidally running mains voltage.
  • PFC active power factor correction
  • boost converters A central component of boost converters, buck converters and PFCs is a choke, which in principle stores energy temporarily and then releases it again when needed becomes.
  • the following explanations are limited to using the throttle in PFC filters. Similar considerations also apply to boost converters and buck converters.
  • a switch connected downstream of the throttle which can set the coil output to a reference potential, is opened and closed by a control device so that on the one hand enough power is delivered to the consumer and on the other hand the current withdrawn from the grid of the mains voltage curve follows in phase.
  • the input power is divided into two coils, which can be switched independently of each other.
  • the switches are operated inversely with each other, i. when one switch is open, the other switch is closed.
  • a choke branch master
  • the switching times for the throttle are determined directly by the controller.
  • the second throttle branch usually follows the master by 180 degrees phases shifted.
  • Such an interleaved arrangement has the advantage that a more efficient power factor correction can be achieved. Since each choke only has to handle half the output power, smaller components can be dimensioned to improve power dissipation and heat generation, enabling more compact PFC circuits. It should be noted that correct operation is also possible with other phase angles ⁇ 180 °. This means that the phase position can be variable in general. However, the majority of applications operate with a phase angle of 180 °.
  • Active PFC circuits usually consist of a rectifier with a step-up step-up converter with a coil and a switch that charges a large capacitor to a voltage above the peak voltage of the AC line voltage.
  • illustration 1 a schematically shows the principle of a boost converter in interleaved technique.
  • the input voltage V IN is applied to the two inductors L1 and L2, and the input current I IN is divided among the two inductors.
  • a respective switch S1 or S2 can set the output of the coil L1 or L2 controlled by a control circuit (not shown) to a reference potential.
  • the outputs of the coils L1 and L2 are connected via a respective diode with a capacitor C OUT , which in cooperation with the coils L1 and L2, the voltage high (boost converter) and smoothes, so that it can be delivered to a load resistor R LOAD .
  • the opening and closing times of the switch S1 are determined by a controller (master), which ensures that on the one hand for the load R LOAD sufficient current I OUT is available and on the other hand, the input current I IN in phase with the input voltage V IN follows.
  • the switch S2 follows the switch S1 by 180 degrees phases shifted (slave).
  • a pulse width modulation of the input current in which the pulse width is controlled by the controller.
  • Fig. 1 b shows the switching behavior of the switches S1 and S2.
  • T on is variable depending on the scheme. In the time in which the switch S1 is closed, the switch S2 is open (180 degrees phase shift).
  • the total time, which results from the sum of the time T on , in which the switch S1 is closed, and the time T off , in which the switch is open, is called period T and is constant.
  • the duty cycle D T on / T is variable and depends on the control. In the FIG. 1b a duty cycle D of constant 0.5 is shown.
  • Fig. 1c shows the currents I1 and I2 through the coils L1 and L2.
  • the current I1 through the coil L1 is composed of a DC component ldc1 and a ripple component lac1 caused by the switching operations.
  • the current I2 through the coil L2 is composed of a DC component ldc2 and a ripple component lac2 (AC component by switching operations). Since the switches are switched 180 degrees in phase, the phase shift between lac1 and lac2 is 180 degrees.
  • the interleaved throttle also works with other phase angles ⁇ 180 °.
  • the duty ratio D shifts at which the maximum of the alternating-current ripple occurs. This means that the phase position can be variable in general. However, the majority of applications operate with a phase angle of 180 °.
  • Fig. 2 schematically shows the coil assembly of this patent with the switches 40 for the interleaved operation.
  • the two coils 20 and 30 are arranged on a common annular core 10, that is, the coil pair 20, 30 operates with strong magnetic coupling, similar to a transformer. Since the magnetic fluxes from the coils add up, the core geometries are correspondingly large, on the one hand to achieve a high magnetic conductivity and on the other hand, do not burden the core to the saturation magnetization.
  • Fig. 3 shows a schematic view of the coil and core configuration of US 8,217,746 B2 ,
  • the core consists of two E-shaped parts 110 and 120 which are separated by an I-shaped part 130.
  • the coils 20 and 30 are wound on the center legs of the E-shaped parts 110 and 120.
  • the cross section A2 of the outer legs can be half as large as the cross section A1 in the middle leg . Since the coils 20 and 30 are wound in anti-phase, the DC components of the magnetic fluxes ⁇ 1 and ⁇ 2 of the coils 20 and 30 in the I-shaped portion 130 largely cancel each other, so that the cross section of the I-shaped portion 130 can also be kept smaller than the cross section A1 in the middle leg of the E-shaped parts 110 and 120.
  • the object is achieved with a choke with two coils and a core according to claim 1.
  • the object is achieved by a choke with two coils and a core, which is characterized in that the core comprises a plurality of core sections having a plurality of outer legs and a center leg, wherein the core is configured so that the core sections two loops with the center leg as a form common portion, wherein each of the two coils is on different loops outside the common portion, that the outer legs have a cross section A1, and that the central leg for the common portion has a cross section A2 ⁇ 2 x A1.
  • a coupling factor k of the two coils of less than 5%, more preferably less than 3%, and more preferably less than 1% can be realized, whereby the core cross sections in the outer legs can be made smaller because the magnetic fields of the coils in the outer legs do not overlap anymore. Further, the magnetic flux corresponding to the DC component of the two coils in the common portion rises, so that the cross section of the common portion can be made small, and thus material can be saved. Because the Coils not coaxial as in the US 8,217,746 B2 are arranged, but sit on the outer legs, less material is needed for the core, resulting in a weight savings. This is achieved for example by the fact that the two coils are arranged on two opposite outer legs.
  • the cross section A2 in the range 0.5 A1 to 0.2 A1, so that further weight can be reduced.
  • the core is designed so that the magnetic resistance in at least one of the outer legs R MA is greater than the magnetic resistance of the center leg R MI .
  • R MA > 20 R MI (5%), R MA > 33 R MI (3%) and R MA > 100 R MI (1%), respectively.
  • a material with high permeability is used for the core section in the middle leg in order to keep the coupling between the two windings or their flows low.
  • a material having a high saturation flux density is preferable to keep the magnetic cross section of the outer legs low.
  • This embodiment with different materials for outer leg and center leg is advantageous only for certain cases where too large a coupling between the two windings and high losses in the middle leg should be avoided.
  • high permeability is generally not necessary because the core is sheared.
  • Common performance ferrites that can be used generally have an initial permeability ⁇ i of 1000 to 3000.
  • High permeability in the middle leg is advantageous because the coupling is reduced.
  • the influence of the permeability of the outer leg on the coupling is negligible, since here the air gap dominates the magnetic resistance. In the middle thigh you will be more likely to use a highly permeable material.
  • the outer leg may have an air gap, which is preferably arranged in the regions of the coils.
  • the core portions are formed from two E-shaped parts that are joined together so that their free ends abut each other, so that the joined middle legs of the two E-shaped parts form the common portion.
  • the outer legs are formed from two U-shaped parts that are joined together so that their free ends abut each other, so that a magnetic circuit is formed, wherein the central leg for the common portion is T-shaped and between the two coils is inserted into the magnetic circuit so that the magnetic circuit is short-circuited, so that the magnetic circuit is divided into the two magnetically weakly coupled loops.
  • this embodiment has the further advantage that only two surfaces abut each other when joining two mold parts in contrast to the E-shaped molding, in which three surfaces abut each other. For three abutting surfaces, the moldings must be made very precisely to avoid uncontrolled air gaps. Due to manufacturing tolerances, these air gaps are almost inevitable. However, in two abutting surfaces such as the U-shaped parts and the T-shaped part, this effect does not occur, so that with this embodiment, chokes can be made with lower tolerances.
  • a height H2 of a vertical part of the T-shaped center leg corresponds to a height H1 of the outer leg.
  • a width B2 of the vertical part of the T-shaped center leg corresponds to a clearance between the two coils
  • a depth T2 of the vertical part of the T-shaped core portion corresponds to an inner distance T1 of opposite outer legs of the magnetic circuit. This contributes to a compact design, since the space between the coils within the magnetic circuit is filled free of play and thus fully usable for the magnetic flux.
  • a horizontal part of the T-shaped center leg rests on an outer leg. Overall, the T-shaped configuration of the center leg allows easy and precise positioning of the magnetic short between the two coils. By the bearing surfaces formed by the horizontal part of the T-shaped center leg, the middle leg is precisely inserted to the correct depth in the magnetic circuit.
  • the outer legs are formed from two U-shaped parts, the free ends of which lie opposite each other and separated from each other by a straight elongated core portion serving as a center leg, play, so that the two loops with the center leg as a common section which form two weakly coupled magnetic circuits.
  • a straight elongated core portion serving as a center leg has the advantage over a T-shaped core portion of avoiding air gaps created between the T-piece and the outer legs. This reduces the coupling between the magnetic circuits.
  • each U-shaped part or E-shaped part is assembled from a plurality of straight pieces. For example, these straight pieces can be glued together to reduce tolerances due to uncontrolled microlube gaps.
  • the core sections are made from a plate stack of soft magnetic material. With this technique, any core shapes can be easily realized with little technical effort.
  • a throttle core comprising a plurality of core sections consisting of a plurality of outer legs and a middle leg.
  • the core sections are arranged so that the core sections form two loops with the center leg as a common section to form two weakly coupled magnetic circuits, wherein the outer legs have a cross section A1 and the center leg for the common section has a cross section A2 smaller than 2 x A1 has.
  • the present invention has been made to provide new chokes with optimized compact core geometry for interleaved topology PFC applications.
  • EV electric vehicle
  • HEV hybrid electric vehicle
  • Fig. 4 shows the principle of the present invention.
  • Two coils 20 and 30 sit on an optimized compact core 200, which consists of several outer legs 230 and 240 and a center leg 250.
  • the outer legs are composed of two coil-carrying outer legs 230 and two lateral outer legs 240, which serve as connecting elements of the coil-carrying outer legs 230, which form a magnetic circuit.
  • the center leg 250 which is parallel to the coil-carrying outer leg 230 and which connects approximately the centers of the lateral outer leg 240, creates a magnetic short between the connecting elements 240 and divides the magnetic circuit into two loops 200-A and 200-B.
  • the outer legs have a cross section A1.
  • the middle leg has a cross section A2 smaller than 2 ⁇ A1.
  • the coils 20 and 30 are connected so that the DC component of the magnetic flux in the middle leg 250 is in opposite directions and thus compensated. Due to the compensated DC flow (DC flow), the cross section of the middle leg can be greatly reduced.
  • the alternating flux of the coils 20 and 30 added However, in the middle leg essentially, since the alternating current amplitudes are due to the antiphase pulse width modulation (see Fig.1c) the PFC control add up in the middle leg due to the reverse polarity of the coils 20 and 30.
  • the maximum change of flux amplitude reduced by the central leg 250 If the outer leg up to a saturation flux density B fed 230 and 240 operated by conventional ferrite materials of 350-400 mT and the ratio of the ripple current is lac lac to the total current + ldc to a value between Set 0.1 and 0.5, the minimum cross section A2 of the center leg 250 can be 0.2 times to the simple of the cross section A1 of the outer leg.
  • the PFC stages are set so that A2 is in the range of 1 x A1 to 0.2 x A1.
  • the magnetic resistance R MA in the outer legs should be 100 times as high as the magnetic resistance R MI in the middle leg.
  • the magnetic fields of the coil 20 do not penetrate into the core region of the outer limbs of the coil 30 and vice versa, as would be the case with a strong coupling.
  • the magnetic fields of the coils would at least partially increase, so that the saturation magnetization in the outer legs would be reached faster. ie, with a strong magnetic coupling of the coils 20 and 30, the core cross section of the outer leg would have to be larger.
  • Fig. 5 shows an implementation of the present invention according to a first embodiment with two E-shaped moldings 210 and 220, which are joined together so that their free ends abut each other.
  • E-shape shows the representation in the Fig. 5 larger gaps L1, L2 and L3 between the free ends of the two E-shaped parts 210 and 220.
  • no gaps L1, L2 and L3 should occur in order to avoid undefined air gaps.
  • the end surfaces at the free ends of the E-shaped parts must be made so precisely that they lie on one plane, so that no air gaps arise.
  • Air gaps are defined, for example, inserted in the side legs 230 in the region of the coils 20 and 30.
  • the cross section A2 of the center leg 250 is smaller than the cross section A1 of the side legs 240 and 230.
  • two U-shaped core parts 260 and 270 may be used, which are joined together so that their free ends abut one another ,
  • Fig. 6a shows a schematic plan view of a core of two U-shaped parts 260 and 270 and a center leg 250 according to a second and third embodiment of the present invention.
  • the butt edges of the free ends of the U-parts 260 and 270 are not visible. They coils 20 and 30 sit on the coil-carrying outer legs 230 of the core.
  • the center leg 250 fills the gap between the coils 20 and 30 and also forms a magnetic short circuit between the lateral outer legs 240, so that there are two magnetic loops.
  • the air gaps L in the side legs 230 in the region of the coils 20 and 30 provide for operation outside the magnetic saturation in the outer legs and at the same time for a low coupling of less than one percent between the two loops 20 and 30.
  • Fig. 6b shows a perspective view of the scheme of Fig. 6a according to a second embodiment with the middle leg 350 pulled out
  • Fig. 6b shows only the core assembly without the coil windings 20 and 30 according to the second embodiment.
  • the core is composed of two U-shaped parts 260 and 270, located at the end faces of the free ends of the U-shaped parts, which in Fig. 6b represented by the line 280, touch. Since only two abutment surfaces 280 are present, it is easier to avoid uncontrolled air gaps in the outer thighs.
  • the distance of the outer legs 240 connecting the coil-carrying outer legs 230 is T1.
  • the middle thigh 350 which in the presentation of Fig. 6b is shown out of the ring structure is T-shaped with a vertical part 350-1 and a horizontal part 350-2.
  • the vertical part 350-1 has a height H2, a length T2 and a width B2.
  • the length T2 of the T-shaped center leg 350 corresponds to the distance T1 between the outer legs 240 and the height H2 of the vertical part of the T-shaped center leg 350 corresponds to the height H1 of the outer legs 230 and 240.
  • the projections of the horizontal part 350-2 of the T -shaped central leg 350 have a length L1 and are respectively on the lateral outer legs 240 on.
  • the maximum length L2 of the horizontal part 350-2 of the T-shaped center leg 350 is at most T1 + 2 ⁇ B1, and the length L1 of the projections of the horizontal part 350-2 resting on the outer legs 240 is approximately B1.
  • the air gaps L in the U-shaped parts 260 and 270 can be realized for example by filling materials such as CEM-1 or FR4.
  • the thickness B2 of the T-shaped center leg 350 is smaller than the width B1 of the outer legs 230 and 240.
  • the Fig. 6c shows a perspective view of the core according to the Fig. 6b in composite form.
  • the reference numerals in Fig. 6c which are identical to the reference numerals of Fig. 6b denote the same technical features and a repetition of the explanation is omitted here.
  • the air spaces between the vertical part 350-1 of the middle limb 350 and the coil-carrying outer limbs 230 (the coils are in Fig. 6c not shown) are almost completely filled by the coil windings.
  • the horizontal portion 350-2 of the T-shaped center leg 350 terminates flush with the outer edges of the outer legs 240.
  • small deviations, ie, protrusions and shelters do not affect the magnetic behavior of the entire core.
  • Fig. 6d shows a perspective view of a core according to a third embodiment of the present invention.
  • the core continues like in the Fig. 6b composed of two U-shaped parts 260 and 270 together.
  • the center leg 450 Between the U-shaped parts 260 and 270 is the center leg 450, so that the free surfaces 280-1 and 280-2 of the open ends of the U-shaped parts 260 and 270 on opposite sides of the center leg 450, the cuboid with a height H3, width B3 and a length of T1 + 2 B1, butt.
  • the size specifications T1, B1 and H1 correspond to the size specifications in Fig. 6b , Incidentally, the U-shaped parts of the Fig. 6b identical to the U-shaped parts of the Fig. 6d be.
  • Fig. 6d shows a schematic three-dimensional arrangement in which the individual elements 260, 270 and 450 are shown exploded. When assembled, the center leg 450 is flexibly bonded to the outer legs 240-a, 240-b, 240-d, and 240-c, whereby tolerances in the outer air gaps L can be intercepted. Low protrusions of the middle leg or slightly shorter middle limbs affect the flow of the outer thighs in the middle leg only insignificantly.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Coils Or Transformers For Communication (AREA)
  • Dc-Dc Converters (AREA)
  • Coils Of Transformers For General Uses (AREA)
EP15160023.6A 2014-04-03 2015-03-20 Inductance et noyau inducteur Active EP2927918B1 (fr)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
DE102014206469.4A DE102014206469A1 (de) 2014-04-03 2014-04-03 Drossel und drosselkern

Publications (3)

Publication Number Publication Date
EP2927918A2 true EP2927918A2 (fr) 2015-10-07
EP2927918A3 EP2927918A3 (fr) 2015-10-21
EP2927918B1 EP2927918B1 (fr) 2023-07-05

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EP15160023.6A Active EP2927918B1 (fr) 2014-04-03 2015-03-20 Inductance et noyau inducteur

Country Status (5)

Country Link
US (1) US10170231B2 (fr)
EP (1) EP2927918B1 (fr)
JP (1) JP2015201642A (fr)
CN (1) CN104979081A (fr)
DE (1) DE102014206469A1 (fr)

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WO2022078769A1 (fr) * 2020-10-15 2022-04-21 Tdk Electronics Ag Inducteur couplé compact
EP4152350A4 (fr) * 2020-06-10 2023-07-26 Huawei Digital Power Technologies Co., Ltd. Inducteur et appareil associé

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WO2022078769A1 (fr) * 2020-10-15 2022-04-21 Tdk Electronics Ag Inducteur couplé compact

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DE102014206469A1 (de) 2015-10-08
CN104979081A (zh) 2015-10-14
US20150287512A1 (en) 2015-10-08
EP2927918B1 (fr) 2023-07-05
US10170231B2 (en) 2019-01-01
JP2015201642A (ja) 2015-11-12
EP2927918A3 (fr) 2015-10-21

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