Magnetic device integration method in phase-shifted full bridge + LLC hybrid bridge arm circuit

Abstract

According to the method for integrating the magnetic devices in the phase-shifted full bridge + LLC hybrid bridge arm circuit, a phase-shifted full bridge transformer, an LLC transformer and an output filter inductor of the phase-shifted full bridge are integrated into two magnetic devices by adopting a magnetic integration technology, and resonant inductors of the phase-shifted full bridge and an LLC converter are replaced by adjusting an air gap to control a leakage inductance value; each magnetic integrated transformer comprises an E-shaped magnetic core and a magnetic cover, the magnetic cover is arranged on the E-shaped magnetic core, and the E-shaped magnetic core comprises three magnetic columns. According to the invention, the utilization efficiency of the magnetic core is optimized, the power density of the power supply is improved, and a novel solution is provided for realizing an aerospace secondary power supply.

Description

TECHNICAL FIELD

[0001] The application relates to aerospace secondary power supply technology, in particular to a magnetic device integration method in a phase-shifted full-bridge+LLC hybrid bridge arm circuit. BACKGROUND

[0002] In view of the requirements of multiple outputs and high power density in aerospace secondary power supply, a phase-shifted full-bridge+LLC circuit based on bridge arm reuse can be used for implementation. In the circuit, the lagging bridge arm of the half-bridge LLC and the phase-shifted full-bridge is reused, which is beneficial to the realization of soft switching of the lagging bridge arm of the phase-shifted full-bridge. However, more magnetic devices, such as transformers, resonant inductors and filter inductors of the phase-shifted full-bridge and the LLC, are introduced in the phase-shifted full-bridge+LLC circuit, which limits the power density of the power supply and increases the volume of the circuit. SUMMARY

[0003] The application aims to provide a magnetic device integration method in a phase-shifted full-bridge+LLC hybrid bridge arm circuit, which integrates the magnetic devices in the circuit by using magnetic integration technology, reduces the number of magnetic devices and improves the power density of the circuit.

[0004] In order to achieve the above-mentioned purpose, the application provides a magnetic device integration method in a phase-shifted full-bridge+LLC hybrid bridge arm circuit, which integrates the magnetic devices in the phase-shifted full-bridge+LLC hybrid bridge arm circuit in two magnetic devices by using magnetic integration technology; each magnetic integration transformer comprises an EI type magnetic core, the EI type magnetic core comprises a mountain-shaped magnet and a magnetic cover, the magnetic cover is arranged on the mountain-shaped magnet, and the mountain-shaped magnet comprises three magnetic columns; the three magnetic columns of the magnetic integration transformer A are a first magnetic column I, a second magnetic column II and a third magnetic column III, the first magnetic column I and the third magnetic column III are located on the two sides of the second magnetic column II respectively; the three magnetic columns of the magnetic integration transformer B are a fourth magnetic column IV, a fifth magnetic column V and a sixth magnetic column VI, the fourth magnetic column IV and the sixth magnetic column VI are located on the two sides of the fifth magnetic column V respectively; the first magnetic column I, the third magnetic column III, the fourth magnetic column IV and the sixth magnetic column VI are all opened with air gaps, and the second magnetic column II and the fifth magnetic column V are not opened with air gaps; the primary winding PSFB_P of the phase-shifted full-bridge is wound on the third magnetic column III and the sixth magnetic column VI; the primary winding LLC_P of the LLC is wound on the first magnetic column I and the fourth magnetic column IV; the secondary winding LLC_S11 and LLC_S12, LLC_S21 and LLC_S22 of the LLC are wound on the first magnetic column I.

[0005] The magnetic device integration method in the phase-shifted full-bridge+LLC hybrid bridge arm circuit, wherein the magnetic devices in the phase-shifted full-bridge+LLC hybrid bridge arm circuit comprise the transformer of the phase-shifted full-bridge, the resonant inductor, the transformer of the LLC, the resonant inductor and the output filter inductor of the phase-shifted full-bridge.

[0006] In the above-mentioned phase-shifted full-bridge + LLC hybrid bridge arm circuit, the magnetic integrated transformer A has the same dimensions as the magnetic integrated transformer B, and the cross-sectional area of ​​the first magnetic column I is equal to the cross-sectional area of ​​the third magnetic column III, the cross-sectional area of ​​the fourth magnetic column IV, and the cross-sectional area of ​​the sixth magnetic column VI.

[0007] In the above-mentioned phase-shifted full-bridge + LLC hybrid bridge arm circuit, the size of the air gap of the first magnetic pillar I is the same as the size of the air gap of the fourth magnetic pillar IV, the size of the air gap of the third magnetic pillar III is the same as the size of the air gap of the sixth magnetic pillar VI, and the size of the air gap of the first magnetic pillar I is different from the size of the air gap of the third magnetic pillar III.

[0008] In the above-mentioned method for integrating magnetic devices in a phase-shifted full-bridge + LLC hybrid bridge arm circuit, the primary winding PSFB_P of the phase-shifted full-bridge is wound in the same direction as the primary winding LLC_P of the LLC; the secondary windings PSFB_S1 and PSFB_S2 of the phase-shifted full-bridge are wound in the opposite direction to the primary winding PSFB_P of the phase-shifted full-bridge; and the secondary windings LLC_S11, LLC_S12, LLC_S21 and LLC_S22 of the LLC are wound in the opposite direction to the primary winding LLC_P of the LLC.

[0009] In the above-mentioned phase-shifted full-bridge + LLC hybrid bridge arm circuit, the magnetic device integration method is described, wherein each winding is a planar winding or a wire winding.

[0010] In the above-mentioned phase-shifted full-bridge + LLC hybrid bridge arm circuit, the magnetic device integration method is as follows: the third magnetic column III, the second magnetic column II, the fourth magnetic column IV, and the sixth magnetic column VI form the magnetic circuit of the phase-shifted full-bridge. For the phase-shifted full-bridge, due to the presence of the secondary rectifier network, the two transformers alternately act as transformers and output filter inductors in one cycle, playing the roles of voltage transformation and filtering, thereby realizing the integration of the output filter inductor and the transformer.

[0011] In the above-mentioned phase-shifted full-bridge + LLC hybrid bridge arm circuit, the magnetic device integration method is described, wherein the first magnetic column I, the second magnetic column II, the fourth magnetic column IV, and the fifth magnetic column V respectively form the magnetic circuits of the two transformers of the LLC.

[0012] The method for integrating magnetic devices in the above-mentioned phase-shifted full-bridge + LLC hybrid bridge arm circuit involves replacing the resonant inductor of the phase-shifted full-bridge and LLC converter by adjusting the air gap size to control the leakage inductance.

[0013] Compared with the prior art, the beneficial technical effects of the present invention are:

[0014] This invention integrates magnetic components in a phase-shifted full-bridge + LLC hybrid bridge arm circuit using magnetic integration technology, resulting in a highly efficient and compact circuit structure. This solves the problem of excessive magnetic components in existing phase-shifted full-bridge + LLC hybrid bridge arm circuits, improves the power density of the circuit, and provides an optimized solution for the application of phase-shifted full-bridge + LLC hybrid bridge arm circuits in aerospace secondary power supplies. Attached Figure Description

[0015] The method for integrating magnetic devices in the phase-shifted full-bridge + LLC hybrid bridge arm circuit of the present invention is given by the following embodiments and figures.

[0016] Figure 1 This is the circuit topology of the phase-shifted full-bridge + LLC hybrid bridge arm circuit of the present invention.

[0017] Figure 2 This is a schematic diagram of the magnetic integrated transformer in the magnetic device integration method of the phase-shifted full-bridge + LLC hybrid bridge arm circuit according to an embodiment of the present invention.

[0018] Figure 3 This is a schematic diagram of the winding arrangement of the magnetic integrated transformer in an embodiment of the present invention.

[0019] Figure 4 This is a schematic diagram of the magnetic device integration method in the phase-shifted full-bridge + LLC hybrid bridge arm circuit according to an embodiment of the present invention.

[0020] Figure 5 This is a magnetic circuit diagram of the magnetic device integration method in the phase-shifted full-bridge + LLC hybrid bridge arm circuit of this invention. Detailed Implementation

[0021] The following will combine Figures 1-5 The method for integrating magnetic devices in the phase-shifted full-bridge + LLC hybrid bridge arm circuit of the present invention will be described in further detail.

[0022] Figure 1 The diagram shown is a circuit topology of the phase-shifted full-bridge + LLC hybrid bridge arm circuit of the present invention.

[0023] This invention employs magnetic integration technology to integrate the magnetic components (including the transformer and resonant inductor of the phase-shifted full-bridge, the transformer and resonant inductor of the LLC, and the output filter inductor of the phase-shifted full-bridge) in the above-mentioned phase-shifted full-bridge + LLC hybrid bridge arm circuit into two magnetic components, thereby reducing the number of magnetic components and improving power density and efficiency.

[0024] like Figures 2 to 4As shown in the embodiment of the present invention, the method for integrating magnetic devices in a phase-shifted full-bridge + LLC hybrid bridge arm circuit integrates the magnetic devices in the phase-shifted full-bridge + LLC hybrid bridge arm circuit, including the transformer and resonant inductor of the phase-shifted full-bridge, the transformer and resonant inductor of the LLC, and the output filter inductor of the phase-shifted full-bridge, into two magnetic integrated transformers. Each magnetic integrated transformer includes an EI-type magnetic core, which includes a mountain-shaped magnet 10 and a magnetic cover 20. The magnetic cover 20 is disposed on the mountain-shaped magnet 10, which includes three magnetic pillars, that is, each magnetic integrated transformer has three magnetic pillars.

[0025] like Figure 2 The three magnetic pillars of the magnetic integrated transformer A are the first magnetic pillar I, the second magnetic pillar II, and the third magnetic pillar III, with the first magnetic pillar I and the third magnetic pillar III located on either side of the second magnetic pillar II. The three magnetic pillars of the magnetic integrated transformer B are the fourth magnetic pillar IV, the fifth magnetic pillar V, and the sixth magnetic pillar VI, with the fourth magnetic pillar IV and the sixth magnetic pillar VI located on either side of the fifth magnetic pillar V. The first magnetic pillar I, the third magnetic pillar III, the fourth magnetic pillar IV, and the sixth magnetic pillar VI all have an air gap 30, meaning that there is a gap between the first magnetic pillar I, the third magnetic pillar III, the fourth magnetic pillar IV, and the sixth magnetic pillar VI and the magnetic cover 20. The second magnetic pillar II and the fifth magnetic pillar V do not have an air gap, meaning that the second magnetic pillar II and the fifth magnetic pillar V are in close contact with the magnetic cover 20. The size of the air gap of the first magnetic column I is the same as the size of the air gap of the fourth magnetic column IV, that is, the distance between the first magnetic column I and the magnetic cover 20 is equal to the distance between the fourth magnetic column IV and the magnetic cover 20; the size of the air gap of the third magnetic column III is the same as the size of the air gap of the sixth magnetic column VI, that is, the distance between the third magnetic column III and the magnetic cover 20 is equal to the distance between the sixth magnetic column VI and the magnetic cover 20; and the size of the air gap of the first magnetic column I is different from the size of the air gap of the third magnetic column III, and the size of the air gap of the fourth magnetic column IV is different from the size of the air gap of the sixth magnetic column VI.

[0026] The specifications (sizes) of magnetic integrated transformer A are the same as those of magnetic integrated transformer B, and the cross-sectional area of ​​the first magnetic column I is equal to the cross-sectional area of ​​the third magnetic column III, the cross-sectional area of ​​the fourth magnetic column IV, and the cross-sectional area of ​​the sixth magnetic column VI.

[0027] like Figure 3 The primary winding PSFB_P of the phase-shifted full-bridge is wound on the third magnetic column III and the sixth magnetic column VI, with N turns. PSFBp Meanwhile, secondary windings PSFB_S1 and PSFB_S2 of a phase-shifted full-bridge are wound on the third magnetic column III and the sixth magnetic column VI, respectively. The number of turns in both secondary windings PSFB_S1 and PSFB_S2 is N. PSFBs The primary winding LLC_P of LLC is wound on the first magnetic post I and the fourth magnetic post IV, with N turns. LLCpThe secondary windings LLC_S11 and LLC_S12, LLC_S21 and LLC_S22 are wound on the first magnetic column I. The number of turns of the secondary windings LLC_S11 and LLC_S12 is N. LLCs1 The secondary winding LLC_S21 and the secondary winding LLC_S22 both have N turns. LLCs2 N LLCs1 =N LLCs2 The primary winding PSFB_P of the phase-shifted full-bridge is wound in the same direction as the primary winding LLC_P of the LLC. The secondary windings PSFB_S1 and PSFB_S2 of the phase-shifted full-bridge are wound on the third magnetic post III and the sixth magnetic post VI, but in opposite directions. The secondary windings LLC_S11, LLC_S12, LLC_S21, and LLC_S22 of the LLC are wound in the opposite direction to the primary winding LLC_P of the LLC. Each winding is either a planar winding or a wire winding.

[0028] From the distribution of the air gap and windings in the magnetic core, it can be seen that the third magnetic column III, the second magnetic column II, the fourth magnetic column IV, and the sixth magnetic column VI form the magnetic circuit of the phase-shifted full bridge. For the phase-shifted full bridge, due to the existence of the secondary rectifier network, transformers A and B alternately act as transformers and filter inductors in one cycle, playing the role of voltage transformation and filtering, thereby realizing the integration of filter inductors and transformers; the first magnetic column I and the second magnetic column II, the fourth magnetic column IV, and the fifth magnetic column V respectively form the magnetic circuits of the two transformers of LLC.

[0029] The magnetic reluctance of both the air gap of the first magnetic column I and the air gap of the fourth magnetic column IV is R. gLLC The magnetic reluctance of the air gaps of the third magnetic column III and the sixth magnetic column VI is R. gPSFB The magnetic reluctance of both the air gap of the second magnetic column II and the air gap of the fifth magnetic column V is R. g The magnetic reluctance of the leakage magnetic circuit between magnetic integrated transformer A and magnetic integrated transformer B is Rair. The integrated magnetic circuit is as follows: Figure 5 As shown.

[0030] Since the air gap reluctance is much greater than the core reluctance, and the leakage circuit reluctance is much greater than the air gap reluctance, the magnetic circuits of the two cores can be analyzed separately, and the magnetic flux expression for each magnetic column can be obtained as follows:

[0031]

[0032] This invention integrates the transformers of a phase-shifted full-bridge + LLC hybrid bridge arm circuit and the output filter inductor of the phase-shifted full-bridge using two three-column transformers. It replaces the resonant inductor of the phase-shifted full-bridge and LLC converter by adjusting the air gap size to control the leakage inductance. This invention optimizes the utilization efficiency of the magnetic core, improves the power density of the power supply, and provides a novel solution for aerospace secondary power supplies.

[0033] This invention retains the advantages of the phase-shifted full-bridge + LLC hybrid bridge arm circuit technology, while optimizing the number of magnetic components in the circuit (i.e. reducing the number of magnetic components), thus solving the problems of large circuit weight and low power density.

Claims

1. A method for integrating magnetic devices in a phase-shifted full-bridge + LLC hybrid bridge arm circuit, characterized in that, Magnetic integration technology is used to integrate the magnetic components in the phase-shifted full-bridge + LLC hybrid bridge arm circuit into two magnetic components; each magnetic integrated transformer includes an EI type magnetic core, the EI type magnetic core includes a mountain-shaped magnet and a magnetic cover, the magnetic cover is disposed on the mountain-shaped magnet, and the mountain-shaped magnet includes three magnetic pillars; The three magnetic pillars of the magnetic integrated transformer A are the first magnetic pillar I, the second magnetic pillar II, and the third magnetic pillar III, with the first magnetic pillar I and the third magnetic pillar III located on either side of the second magnetic pillar II. The three magnetic pillars of the magnetic integrated transformer B are the fourth magnetic pillar IV, the fifth magnetic pillar V, and the sixth magnetic pillar VI, with the fourth magnetic pillar IV and the sixth magnetic pillar VI located on either side of the fifth magnetic pillar V. The first magnetic pillar I, the third magnetic pillar III, the fourth magnetic pillar IV, and the sixth magnetic pillar VI all have air gaps, while the second magnetic pillar II and the fifth magnetic pillar V do not have air gaps. The primary winding PSFB_P of the phase-shifted full-bridge is wound on the third magnetic column III and the sixth magnetic column VI; the primary winding LLC_P of LLC is wound on the first magnetic column I and the fourth magnetic column IV; the secondary winding LLC_S11 and LLC_S12 of LLC is wound on the first magnetic column I; and the secondary winding LLC_S21 and LLC_S22 of LLC is wound on the fourth magnetic column IV.

2. The method for integrating magnetic devices in the phase-shifted full-bridge + LLC hybrid bridge arm circuit as described in claim 1, characterized in that, The magnetic components in the phase-shifted full-bridge + LLC hybrid bridge arm circuit include the transformer and resonant inductor of the phase-shifted full-bridge, the transformer and resonant inductor of the LLC, and the output filter inductor of the phase-shifted full-bridge.

3. The method for integrating magnetic devices in the phase-shifted full-bridge + LLC hybrid bridge arm circuit as described in claim 1, characterized in that, The dimensions of magnetic integrated transformer A are the same as those of magnetic integrated transformer B, and the cross-sectional area of ​​the first magnetic column I is equal to the cross-sectional area of ​​the third magnetic column III, the cross-sectional area of ​​the fourth magnetic column IV, and the cross-sectional area of ​​the sixth magnetic column VI.

4. The method for integrating magnetic devices in the phase-shifted full-bridge + LLC hybrid bridge arm circuit as described in claim 3, characterized in that, The size of the air gap of the first magnetic column I is the same as the size of the air gap of the fourth magnetic column IV, the size of the air gap of the third magnetic column III is the same as the size of the air gap of the sixth magnetic column VI, and the size of the air gap of the first magnetic column I is different from the size of the air gap of the third magnetic column III.

5. The method for integrating magnetic devices in the phase-shifted full-bridge + LLC hybrid bridge arm circuit as described in claim 1, characterized in that, The primary winding PSFB_P of the phase-shifted full-bridge is wound in the same direction as the primary winding LLC_P of the LLC; the secondary windings PSFB_S1 and PSFB_S2 of the phase-shifted full-bridge are wound in the opposite direction to the primary winding PSFB_P of the phase-shifted full-bridge; the secondary windings LLC_S11, LLC_S12, LLC_S21 and LLC_S22 of the LLC are wound in the opposite direction to the primary winding LLC_P of the LLC.

6. The method for integrating magnetic devices in the phase-shifted full-bridge + LLC hybrid bridge arm circuit as described in claim 1, characterized in that, Each winding is either a planar winding or a wire winding.

7. The method for integrating magnetic devices in the phase-shifted full-bridge + LLC hybrid bridge arm circuit as described in claim 1, characterized in that, The third magnetic column III, the second magnetic column II, the fourth magnetic column IV, and the sixth magnetic column VI form the magnetic circuit of the phase-shifted full bridge. For the phase-shifted full bridge, due to the presence of the secondary rectifier network, the two transformers alternately act as transformers and output filter inductors in one cycle, playing the roles of voltage transformation and filtering, thereby realizing the integration of the output filter inductor and the transformer.

8. The method for integrating magnetic devices in the phase-shifted full-bridge + LLC hybrid bridge arm circuit as described in claim 1, characterized in that, The first magnetic column I, the second magnetic column II, the fourth magnetic column IV, and the fifth magnetic column V respectively form the magnetic circuits of the two transformers of LLC.

9. The method for integrating magnetic devices in the phase-shifted full-bridge + LLC hybrid bridge arm circuit as described in claim 1, characterized in that, The leakage inductance is controlled by adjusting the air gap size to replace the resonant inductance of the phase-shifted full-bridge and LLC converter.

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