A design method for integrated inductor and related components

Abstract

The present invention discloses a design method for an integrated inductor and related components, relating to the field of integrated inductor design. The method includes determining the equivalent magnetic circuit of the magnetic core based on its structure; determining the magnetic flux of each phase in the magnetic core based on the equivalent magnetic circuit; determining the cross-sectional area of ​​the winding post, the cross-sectional area of ​​the common magnetic yoke, and the cross-sectional area of ​​the decoupling magnetic yoke based on the maximum magnetic flux; determining the length of the winding post for each phase based on the number of turns of the winding, the maximum DC bias current of the integrated inductor, the equivalent magnetic circuit length of the winding post, and the equivalent magnetic circuit lengths of the common magnetic yoke and the decoupling magnetic yoke; and determining the size of the integrated inductor based on the cross-sectional area of ​​the winding post, the cross-sectional area of ​​the common magnetic yoke, the cross-sectional area of ​​the decoupling magnetic yoke, and the length of the winding post for each phase. By integrating the inductors, multiple staggered parallel inductors share a single magnetic core, thereby reducing the volume and weight of the converter.

Description

Technical Field

[0001] The present invention relates to the field of integrated inductor design, and in particular to a design method of an integrated inductor and related components. Background Art

[0002] As the power levels of multiphase power converters continue to increase, the number of inductors in interleaved parallel DC-DC converters is increasing. This significantly increases the size and weight of the inductors, increasing the cost of the power converter and reducing its power density. Interleaving parallel refers to breaking down a large periodic power source into several smaller power sources, allowing these smaller power sources to operate at the same frequency with a certain phase difference. As the power levels of DC-DC converters continue to increase, the voltage and current stresses on the components are also increasing, even exceeding their tolerances, resulting in higher component costs and losses. Multiphase interleaved parallel technology has been widely used due to its advantages in reducing the voltage and current stress of the switch tubes, reducing total current ripple, increasing converter capacity, and improving efficiency and power density. Although multiphase interleaved parallel technology has many advantages in improving converter efficiency and performance, it increases the number of magnetic components and switching devices in the converter, which limits further increases in converter power density. Magnetic components account for a significant portion of the volume and weight of DC-DC converters and have a significant impact on converter performance. Therefore, how to balance improving the efficiency of the converter while reducing the volume and weight of the integrated inductor is an urgent problem to be solved in existing technologies. Summary of the Invention

[0003] The purpose of the present invention is to provide a design method for an integrated inductor and related components, by integrating the inductor and sharing a magnetic core with multiple inductors connected in parallel, thereby reducing the volume and weight of the converter.

[0004] To solve the above technical problems, the present invention provides a design method for an integrated inductor. The magnetic core of the integrated inductor includes an upper common yoke, a lower common yoke, a decoupling yoke, a winding post and a winding. The winding post includes a left winding post and a right winding post. The first decoupling yoke to the n-1th decoupling yoke are sequentially arranged between the upper common yoke and the lower common yoke. The upper part of the i-th decoupling yoke is connected to the i-th phase left winding post and the i-th phase right winding post, and the lower part is connected to the i+1th phase left winding post and the i+1th phase right winding post. The upper common yoke is connected to the first phase left winding post and the first phase right winding post, respectively. The lower common yoke is connected to the n-th phase left winding post and the n-th phase right winding post, respectively. N / 2 turns of winding are wound on the left winding post and the right winding post of each phase, 1<i<n, i and n are both integers.

[0005] The design method of the integrated inductor includes:

[0006] Determining an equivalent magnetic circuit of the magnetic core according to the structure of the magnetic core of the integrated inductor;

[0007] determining the magnetic flux of each phase in the magnetic core according to the equivalent magnetic circuit;

[0008] determining the cross-sectional area of ​​the winding column, the cross-sectional area of ​​the common magnetic yoke, and the cross-sectional area of ​​the decoupling magnetic yoke according to the maximum value of the magnetic flux;

[0009] Determining the length of each phase winding post according to the number of turns of the winding, the maximum DC bias current of the integrated inductor, the equivalent magnetic path length of the winding post, and the equivalent magnetic path lengths of the common magnetic yoke and the decoupling magnetic yoke;

[0010] The size of the integrated inductor is determined according to the cross-sectional area of ​​the winding post, the cross-sectional area of ​​the common magnetic yoke, the cross-sectional area of ​​the decoupling magnetic yoke, and the length of each phase winding post.

[0011] On the other hand, determining the equivalent magnetic circuit of the magnetic core according to the structure of the magnetic core of the integrated inductor includes:

[0012] The magnetomotive force, winding rod reluctance, common yoke reluctance and decoupling yoke reluctance in the equivalent magnetic circuit of the magnetic core are determined according to the structure of the magnetic core of the integrated inductor.

[0013] On the other hand, the magnetomotive force, winding rod reluctance, common yoke reluctance and decoupling yoke reluctance in the equivalent magnetic circuit of the magnetic core of the integrated inductor are determined according to the structure of the magnetic core of the integrated inductor, including:

[0014] Determining the connection relationship between the magnetomotive force, winding rod reluctance, common yoke reluctance and decoupling yoke reluctance in the equivalent magnetic circuit of the magnetic core according to the structure of the magnetic core of the integrated inductor;

[0015] The connection relationship includes the first end of the i-th decoupling yoke magnetic resistance being connected to the negative end of the i-th magnetomotive force and the first end of the i+1-th winding magnetic resistance, the positive end of the i-th magnetomotive force being connected to the first end of the i-th winding post magnetic resistance, the second end of the i-th winding post magnetic resistance being connected to the first end of the i-1-th decoupling yoke magnetic resistance, and the second end of the i-1-th decoupling yoke magnetic resistance being connected to the second end of the i-th decoupling yoke magnetic resistance; the first end of the first common magnetic yoke magnetic resistance being connected to the second end of the first winding post magnetic resistance, the second end of the first common magnetic yoke magnetic resistance being connected to the second end of each of the decoupling yoke magnetic resistances and the second end of the second common magnetic yoke magnetic resistance, and the first end of the second common magnetic yoke magnetic resistance being connected to the negative end of the n-th magnetomotive force, where i is an integer greater than 1.

[0016] On the other hand, determining the magnetic flux of each phase in the magnetic core according to the equivalent magnetic circuit includes:

[0017] Determine the magnetic flux of each decoupling yoke. The relationship between the magnetic flux of each phase is: ;

[0018] Where, Φ1(t) is the magnetic flux between the upper common yoke and the first phase winding column, Φ n (t) is the magnetic flux between the lower common yoke and the n-phase winding, Φ j1 (t) is the magnetic flux of the first decoupling yoke, Φ j(n-1)1 (t) is the magnetic flux of the n-1th decoupling yoke, i L1 (t) is the current flowing through the first phase winding, i Ln (t) is the current flowing through the n-th phase winding, and R is the magnetic resistance of the winding column.

[0019] On the other hand, before determining the cross-sectional area of ​​the winding column, the cross-sectional area of ​​the common magnetic yoke, and the cross-sectional area of ​​the decoupling magnetic yoke according to the maximum value of the magnetic flux, the method further includes:

[0020] Determine the maximum value of the magnetic flux, the expression of the maximum value of the magnetic flux is ;

[0021] Among them, Φ max is the maximum value of the magnetic flux, Φ dc is the DC magnetic flux, △Φ is the AC magnetic flux;

[0022] Enter the step of determining the cross-sectional area of ​​the winding column, the cross-sectional area of ​​the common magnetic yoke, and the cross-sectional area of ​​the decoupling magnetic yoke according to the maximum value of the magnetic flux.

[0023] On the other hand, the process of determining the DC magnetic flux includes:

[0024] The DC flux is determined according to the number of turns of the winding wound on each phase winding column, the maximum DC bias current, the magnetic resistance of the upper common magnetic yoke, the magnetic resistance of the lower common magnetic yoke, the magnetic resistance of the decoupling magnetic yoke and the DC flux relationship. The DC flux relationship is: ;

[0025] Wherein, R is the magnetic resistance of the winding column, R m is the magnetic resistance of each decoupling yoke, R m1 is the magnetic resistance of the upper common yoke and the lower common yoke, I dc is the maximum DC bias current, and L1 is the self-inductance of the first phase inductor.

[0026] On the other hand, the process of determining the self-inductance of the first phase inductor includes:

[0027] The self-inductance of each phase is determined based on the magnetic resistance of the winding rod, the magnetic resistance of each decoupling magnetic yoke, the magnetic resistance of the upper common magnetic yoke and the magnetic resistance of the lower common magnetic yoke. The expression of the self-inductance is: ;

[0028] Among them, L1 is the self-inductance of the first phase inductor, L n is the self-inductance of the first phase inductor, R is the magnetic resistance of the winding column, R m is the magnetic resistance of each decoupling yoke, R m1 is the magnetic resistance of the upper common yoke and the lower common yoke.

[0029] On the other hand, determining the cross-sectional area of ​​the left winding post of each phase and the cross-sectional area of ​​the right winding post of each phase according to the maximum value of the magnetic flux includes:

[0030] The cross-sectional area of ​​each phase of the winding post on the XY plane is determined according to the maximum value of the magnetic flux and the maximum magnetic density of the winding post core material. The relationship between the cross-sectional area of ​​the winding post on the XY plane is: ;

[0031] Among them, Φ max is the maximum value of the magnetic flux, B m1 is the maximum magnetic density of the winding core material, △Φ is the AC magnetic flux, L1 is the self-inductance of the first phase inductor, I dc is the maximum DC bias current, V i is the input voltage of the integrated inductor, V o is the output voltage of the integrated inductor, D is the duty cycle, T s is the switching cycle.

[0032] On the other hand, determining the cross-sectional area of ​​the common magnetic yoke according to the maximum value of the magnetic flux includes:

[0033] The cross-sectional area of ​​the common yoke on the YZ plane of each phase is determined according to the maximum value of the magnetic flux and the maximum magnetic density of the common yoke core material. The relationship between the cross-sectional area of ​​the common yoke on the YZ plane is: ;

[0034] Among them, Φ max is the maximum value of the magnetic flux, B m2 is the maximum magnetic density of the common yoke core material, △Φ is the AC magnetic flux, L1 is the self-inductance of the first phase inductor, I dc is the maximum DC bias current, V i is the input voltage of the integrated inductor, V o is the output voltage of the integrated inductor, D is the duty cycle, T s is the switching cycle.

[0035] On the other hand, determining the cross-sectional area of ​​the decoupling yoke according to the maximum value of the magnetic flux includes:

[0036] determining a maximum magnetic flux of the decoupling yoke;

[0037] The cross-sectional area of ​​the decoupling yoke on the YZ plane is determined according to the maximum magnetic flux, and the expression of the cross-sectional area is: ;

[0038] Among them, Φ j1max is the maximum magnetic flux of the decoupling yoke, A ej1 To A ej(n-1) is the cross-sectional area of ​​the decoupling yoke on the YZ surface, V i is the input voltage of the integrated inductor, V o is the output voltage of the integrated inductor, D is the duty cycle, T s is the switching period, B m2 is the maximum magnetic flux density of the decoupling yoke core material.

[0039] On the other hand, determining the length of each phase winding post according to the number of turns of the winding, the maximum DC bias current of the integrated inductor, the equivalent magnetic path length of the winding post, and the equivalent magnetic path lengths of the common magnetic yoke and the decoupling magnetic yoke includes:

[0040] The maximum DC bias current is determined according to the number of turns of the winding, the magnetic field strength in the winding post, the magnetic field strength in the common magnetic yoke and the decoupling magnetic yoke, the equivalent magnetic path length of the winding post, and the equivalent magnetic path length of the common magnetic yoke and the decoupling magnetic yoke. The relationship between the maximum DC bias current is: ;

[0041] Wherein, H1 is the magnetic field strength in the winding column, H2 is the magnetic field strength in the common magnetic yoke and the decoupling magnetic yoke, l eq1 is the equivalent magnetic circuit length of the winding column, l eq2 is the equivalent magnetic path length of the common yoke and the decoupling yoke, I dc is the maximum DC bias current;

[0042] Determine the relationship between the maximum magnetic flux density of the winding column and the maximum magnetic flux density and magnetic permeability of the ordinary magnetic yoke and the decoupling magnetic yoke. The expression for the relationship between the magnetic flux density, magnetic permeability and magnetic field strength is: ;

[0043] Among them, B m1 is the maximum magnetic density of the winding column, μ1 is the magnetic permeability of the winding column, B m2 is the maximum magnetic density of the common magnetic yoke and the decoupling magnetic yoke, μ2 is the magnetic permeability of the common magnetic yoke and the decoupling magnetic yoke;

[0044] determining the magnetic resistance of the winding bobbin based on the magnetic permeability;

[0045] The length of the winding post is determined according to the magnetic resistance of the winding post.

[0046] To solve the above technical problems, the present invention also provides a design system for an integrated inductor. The magnetic core of the integrated inductor includes an upper common yoke, a lower common yoke, a decoupling yoke, a winding post and a winding. The winding post includes a left winding post and a right winding post. The first decoupling yoke to the n-1th decoupling yoke are sequentially arranged between the upper common yoke and the lower common yoke. The upper part of the i-th decoupling yoke is connected to the i-th phase left winding post and the i-th phase right winding post, and the lower part is connected to the i+1th phase left winding post and the i+1th phase right winding post. The upper common yoke is respectively connected to the first phase left winding post and the first phase right winding post, and the lower common yoke is respectively connected to the n-th phase left winding post and the n-th phase right winding post. Each phase left winding post and right winding post are wound with N / 2 turns of winding, 1<i<n, i and n are both integers. The design system for the integrated inductor includes:

[0047] an equivalent magnetic circuit determining unit, configured to determine an equivalent magnetic circuit of the magnetic core according to the structure of the magnetic core of the integrated inductor;

[0048] a magnetic flux determining unit, configured to determine the magnetic flux of each phase in the magnetic core according to the equivalent magnetic circuit;

[0049] a cross-sectional area determining unit, configured to determine the cross-sectional area of ​​the winding column, the cross-sectional area of ​​the common magnetic yoke, and the cross-sectional area of ​​the decoupling magnetic yoke according to the maximum value of the magnetic flux;

[0050] a length determining unit, configured to determine the length of each phase winding post according to the number of turns of the winding, the maximum DC bias current of the integrated inductor, the equivalent magnetic path length of the winding post, and the equivalent magnetic path lengths of the common magnetic yoke and the decoupling magnetic yoke;

[0051] A size determining unit is used to determine the size of the integrated inductor according to the cross-sectional area of ​​the winding post, the cross-sectional area of ​​the common magnetic yoke, the cross-sectional area of ​​the decoupling magnetic yoke, and the length of each phase winding post.

[0052] To solve the above technical problems, the present invention further provides a design device for an integrated inductor, comprising:

[0053] memory for storing computer programs;

[0054] A processor is configured to implement the steps of the above-mentioned integrated inductor design method when executing the computer program.

[0055] In order to solve the above technical problems, the present invention also provides an integrated inductor, the magnetic core of the integrated inductor includes an upper common yoke, a lower common yoke, a decoupling yoke, a winding post and a winding, the winding post includes a left winding post and a right winding post, the first decoupling yoke to the n-1th decoupling yoke are sequentially arranged between the upper common yoke and the lower common yoke, the upper part of the i-th decoupling yoke is connected to the i-th phase left winding post and the i-th phase right winding post, and the lower part is connected to the i+1-th phase left winding post and the i+1-th phase right winding post, the upper common yoke is respectively connected to the first phase left winding post and the first phase right winding post, the lower common yoke is respectively connected to the n-th phase left winding post and the n-th phase right winding post, each phase left winding post and right winding post are wound with N / 2 turns of winding, 1<i<n, i and n are both integers.

[0056] To solve the above technical problem, the present invention further provides a computer-readable storage medium having a computer program stored thereon. When the computer program is executed by a processor, the steps of the above-mentioned integrated inductor design method are implemented.

[0057] The present invention discloses a design method for an integrated inductor and related components, relating to the field of integrated inductor design. The method includes determining the equivalent magnetic circuit of the magnetic core based on the structure of the integrated inductor; determining the magnetic flux of each phase in the magnetic core based on the equivalent magnetic circuit; determining the cross-sectional area of ​​the winding post, the cross-sectional area of ​​the common magnetic yoke, and the cross-sectional area of ​​the decoupling magnetic yoke based on the maximum value of the magnetic flux; determining the length of the winding post for each phase based on the number of turns of the winding, the maximum bias DC current of the integrated inductor, the equivalent magnetic circuit length of the winding post, and the equivalent magnetic circuit lengths of the common magnetic yoke and the decoupling magnetic yoke; and determining the size of the integrated inductor based on the cross-sectional area of ​​the winding post, the cross-sectional area of ​​the common magnetic yoke, the cross-sectional area of ​​the decoupling magnetic yoke, and the length of the winding post for each phase. By integrating the inductors, multiple staggered parallel inductors share a single magnetic core, thereby reducing the volume and weight of the converter. BRIEF DESCRIPTION OF THE DRAWINGS

[0058] In order to more clearly illustrate the technical solutions in the embodiments of the present invention, the following briefly introduces the prior art and the drawings required for use in the embodiments. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0059] Figure 1 A flow chart of a design method for an integrated inductor provided by the present invention;

[0060] Figure 2 A front view of an n-phase staggered parallel integrated inductor provided by the present invention;

[0061] Figure 3A schematic structural diagram of an n-phase interleaved parallel DC-DC converter provided by the present invention;

[0062] Figure 4 A waveform diagram of a phase inductor current in a current continuous mode provided by the present invention;

[0063] Figure 5 A top view of an n-phase staggered parallel integrated inductor provided by the present invention;

[0064] Figure 6 A side view of an n-phase staggered parallel integrated inductor provided by the present invention;

[0065] Figure 7 A schematic diagram of an equivalent magnetic circuit of an n-phase integrated inductor provided by the present invention;

[0066] Figure 8 A schematic diagram of an equivalent magnetic circuit of an n-phase integrated inductor provided by the present invention with the magnetomotive force source except the first phase set to zero;

[0067] Figure 9 A diagram showing the influence of different decoupling phase sequences on the peak magnetic flux on the decoupling yoke provided by the present invention;

[0068] Figure 10 A waveform diagram of the n-phase inductor terminal voltage, the magnetic flux of the left and right winding legs of the inductor, and the magnetic flux of the decoupling yoke provided by the present invention;

[0069] Figure 11 A schematic structural diagram of a design system for an integrated inductor provided by the present invention;

[0070] Figure 12 A schematic structural diagram of a design device for an integrated inductor provided by the present invention; DETAILED DESCRIPTION

[0071] The core of the present invention is to provide a design method for an integrated inductor and related components. By integrating the inductor and allowing multiple inductors connected in parallel to share a magnetic core, the volume and weight of the converter are reduced.

[0072] To make the objectives, technical solutions, and advantages of the embodiments of the present invention more clear, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts shall fall within the scope of protection of the present invention.

[0073] Figure 1 This is a flow chart of a design method for an integrated inductor provided by the present invention. Figure 2A front view of an n-phase staggered parallel integrated inductor provided by the present invention;

[0074] The magnetic core of the integrated inductor includes an upper common yoke, a lower common yoke, a decoupling yoke, a winding post and a winding, wherein the winding post includes a left winding post and a right winding post, and the first decoupling yoke to the n-1th decoupling yoke are sequentially arranged between the upper common yoke and the lower common yoke. The upper part of the i-th decoupling yoke is connected to the i-th phase left winding post and the i-th phase right winding post, and the lower part is connected to the i+1-th phase left winding post and the i+1-th phase right winding post. The upper common yoke is connected to the first phase left winding post and the first phase right winding post respectively, and the lower common yoke is connected to the n-th phase left winding post and the n-th phase right winding post respectively. N / 2 turns of winding are wound on the left winding post and the right winding post of each phase, where 1<i<n, and i and n are both integers.

[0075] The design method of the integrated inductor includes:

[0076] S11: Determine the equivalent magnetic circuit of the magnetic core according to the structure of the magnetic core of the integrated inductor;

[0077] S12: Determine the magnetic flux of each phase in the magnetic core based on the equivalent magnetic circuit;

[0078] S13: determining the cross-sectional area of ​​the winding column, the cross-sectional area of ​​the common magnetic yoke, and the cross-sectional area of ​​the decoupling magnetic yoke according to the maximum value of the magnetic flux;

[0079] S14: determining the length of each phase winding post according to the number of turns of the winding, the maximum DC bias current of the integrated inductor, the equivalent magnetic path length of the winding post, and the equivalent magnetic path lengths of the common magnetic yoke and the decoupling magnetic yoke;

[0080] S15: Determine the size of the integrated inductor according to the cross-sectional area of ​​the winding post, the cross-sectional area of ​​the common magnetic yoke, the cross-sectional area of ​​the decoupling magnetic yoke, and the length of each phase winding post.

[0081] Interleaving parallel circuits breaks down a large, periodic power source into several smaller ones, allowing them to operate at the same frequency with a certain phase difference. As the power levels of DC-DC converters continue to increase, the voltage and current stresses on the components are increasing, sometimes exceeding their tolerances. This leads to higher costs and losses. Multiphase interleaving parallel circuits are widely used because they reduce the voltage and current stresses on the switching tubes, reduce total current ripple, increase converter capacity, and improve efficiency and power density.

[0082] While multiphase interleaved parallel technology offers numerous advantages in improving converter efficiency and performance, it increases the number of magnetic components and switching devices in the converter, limiting further increases in converter power density. Magnetic components contribute significantly to the volume and weight of the converter and significantly impact converter performance. Therefore, magnetic integration technology is needed to further optimize the performance of interleaved parallel converters.

[0083] Figure 3 A schematic diagram of the structure of an n-phase interleaved parallel DC-DC converter provided by the present invention. Figure 4 A waveform diagram of a phase inductor current in a current continuous mode provided by the present invention;

[0084] Figure 3 Middle C H 、C L They are filter capacitors on the high and low voltage sides of the circuit, L1, L2...L n is the inductance of each phase, i L1 、i L2 …i Ln is the current of the inductor of each phase, is the sum of the inductor currents of each phase, u L1 、u L2 …u Ln is the voltage across the inductor of each phase. H When the input voltage is V, the topology can be regarded as consisting of n Buck circuits in parallel, as a step-down circuit, and the output load voltage is V L MOS tubes S1, S2...S n As a power switch tube, MOS tube S n+1 、S n+2 …S 2n As a synchronous rectifier to replace the diode in the Buck circuit, it is called Buck working mode; when the low-voltage side V L When the input voltage is V, the topology can be regarded as consisting of n Boost circuits in parallel. As a boost circuit, the output voltage is V H MOS tube S n+1 、S n+2 …S 2n As power switch tubes, MOS tubes S1, S2...S n Using a synchronous rectifier to replace the diode in the Boost circuit is called Boost operating mode.

[0085] Taking Buck mode as an example, S1, S2…S n Main power tube, S n+1 、S n+2 …S 2nAs a synchronous rectifier to replace the diode in the Buck circuit. Assume the inductance of the first phase is L1 and the switching period is T S , the driving signal of the switch tube S1 is u s1 , its duty cycle is D, and the average current of each phase inductor is I dc , the total output power is P.

[0086] like Figure 4 As shown, when the switch tube S1 is turned on, the switch tube S n+1 Cut-off, at this time the voltage across the first phase inductor is positive, its value is V i −V o , so the first-phase inductor current rises, and the increment of the first-phase inductor current is When the switch tube S1 is turned off, the diode S n+1 The voltage across the first phase inductor is negative, and its value is −V o , so the first-phase inductor current decreases, and the reduction in the first-phase inductor current is , from which the first phase inductor current ripple can be obtained as , the minimum inductor current is .

[0087] This application discloses a design method for an n-phase, highly decoupled integrated inductor, addressing the cost, volume, and weight issues of existing n-phase power converters. The n-phase integrated inductor's magnetic core comprises two conventional yokes, (n-1) decoupling yokes, and 2n winding posts. The yokes are constructed from high-permeability magnetic materials, such as ferrite. The winding posts are constructed from low-permeability magnetic materials, such as powder core.

[0088] Figure 2 A front view of an n-phase staggered parallel integrated inductor provided by the present invention, Figure 5 A top view of an n-phase staggered parallel integrated inductor provided by the present invention, Figure 6 A side view of an n-phase staggered parallel integrated inductor provided by the present invention;

[0089] The N turns of winding for each phase are wound on the left and right winding poles, and the number of turns on the left and right winding poles is N / 2.

[0090] The left and right winding posts of the first phase can have air gaps with the upper common yoke and the first decoupling yoke. The left and right winding posts of the second phase can have air gaps with the first and second decoupling yokes. The left and right winding posts of the nth phase can have air gaps with the lower common yoke and the (n-1)th decoupling yoke. The first decoupling yoke is located between the first and second phase winding posts. The second decoupling yoke is located between the second and third phase winding posts. The (n-1)th decoupling yoke is located between the (n-1)th and nth phase winding posts. The Z-direction height of the (n-1) decoupling yokes is less than the Z-direction height of the two common yokes. The Y-direction depth of the two common yokes and the (n-1)th decoupling yoke is greater than the Y-direction depth of all winding posts. The core cross-sectional area of ​​the winding posts in the XY plane is less than the core cross-sectional area of ​​the two common yokes in the YZ plane.

[0091] Therefore, after the integrated inductor is designed, the dimensions of each element in the integrated inductor, such as the cross-sectional area and length, need to be designed in order to determine the dimensions of the integrated inductor.

[0092] The present invention discloses a design method for an integrated inductor, which relates to the field of integrated inductor design. The method includes determining an equivalent magnetic circuit of the magnetic core based on the structure of the integrated inductor; determining the magnetic flux of each phase in the magnetic core based on the equivalent magnetic circuit; determining the cross-sectional area of ​​the winding post, the cross-sectional area of ​​the common magnetic yoke, and the cross-sectional area of ​​the decoupling magnetic yoke based on the maximum value of the magnetic flux; determining the length of the winding post for each phase based on the number of turns of the winding, the maximum DC bias current of the integrated inductor, the equivalent magnetic circuit length of the winding post, and the equivalent magnetic circuit lengths of the common magnetic yoke and the decoupling magnetic yoke; and determining the size of the integrated inductor based on the cross-sectional area of ​​the winding post, the cross-sectional area of ​​the common magnetic yoke, the cross-sectional area of ​​the decoupling magnetic yoke, and the length of the winding post for each phase. By integrating the inductors, multiple staggered parallel inductors share a single magnetic core, thereby reducing the volume and weight of the converter.

[0093] Based on the above embodiment:

[0094] Figure 7 A schematic diagram of an equivalent magnetic circuit of an n-phase integrated inductor provided by the present invention;

[0095] Figure 8 A schematic diagram of an equivalent magnetic circuit of an n-phase integrated inductor provided by the present invention with the magnetomotive force source except the first phase set to zero;

[0096] In some embodiments, determining an equivalent magnetic circuit of a magnetic core according to a structure of a magnetic core of an integrated inductor includes:

[0097] The equivalent magnetic circuit of the inductor is determined based on the winding rod reluctance, magnetomotive force, ordinary yoke reluctance and decoupled yoke reluctance.

[0098] In some embodiments, determining the equivalent magnetic circuit of the inductor based on the winding rod reluctance, the magnetomotive force, the common yoke reluctance, and the decoupled yoke reluctance includes:

[0099] Determine the equivalent magnetic circuit of the inductor based on the winding rod reluctance, magnetomotive force, ordinary yoke reluctance, decoupling yoke reluctance and connection relationship;

[0100] The connection relationship includes the first end of the i-th decoupling yoke magnetic resistance being connected to the negative end of the i-th magnetomotive force and the first end of the i+1-th winding pole magnetic resistance, the positive end of the i-th magnetomotive force being connected to the first end of the i-th winding pole magnetic resistance, the second end of the i-th winding pole magnetic resistance being connected to the first end of the i-1-th decoupling yoke magnetic resistance, and the second end of the i-1-th decoupling yoke magnetic resistance being connected to the second end of the i-th decoupling yoke magnetic resistance; the first end of the first common magnetic yoke magnetic resistance being connected to the second end of the first winding pole magnetic resistance, the second end of the first common magnetic yoke magnetic resistance being connected to the second end of each decoupling yoke magnetic resistance and the second end of the second common magnetic yoke magnetic resistance, and the first end of the second common magnetic yoke magnetic resistance being connected to the negative end of the n-th magnetomotive force, where i is an integer greater than 1.

[0101] In some embodiments, determining the magnetic flux of each phase in the magnetic core according to the equivalent magnetic circuit includes:

[0102] Determine the magnetic flux of each decoupling yoke reluctance as the magnetic flux of the corresponding phase. The relationship between the magnetic flux of each phase is: ;

[0103] Where, Φ1(t) is the magnetic flux between the upper common yoke and the first phase winding column, Φ n (t) is the magnetic flux between the lower common yoke and the n-phase winding, Φ j1 (t) is the magnetic flux of the first decoupling yoke, Φ j(n-1) (t) is the magnetic flux of the n-1th decoupling yoke, i L1 (t) is the current flowing through the first phase winding, i Ln (t) is the current flowing through the n-phase winding, and R is the magnetic resistance of the winding.

[0104] Φ j1 The positive direction of (t) is as follows Figure 2 As shown; Φ j2 The positive direction of (t) is as follows Figure 2 As shown; R m1 is the magnetic resistance of the upper and lower common magnetic yokes, which is ideally zero due to the use of high magnetic permeability core materials; R m is the magnetic resistance of each decoupling yoke, which is ideally zero due to the use of high permeability core material. R is the total magnetic resistance of the left and right windings of each phase.

[0105] In some embodiments, before determining the cross-sectional area of ​​the winding rod, the cross-sectional area of ​​the common magnetic yoke, and the cross-sectional area of ​​the decoupling magnetic yoke according to the maximum value of the magnetic flux, the method further includes:

[0106] Determine the maximum value of the magnetic flux. The expression for the maximum value of the magnetic flux is ;

[0107] Among them, Φ max is the maximum value of magnetic flux, Φ dc is the DC magnetic flux, △Φ is the AC magnetic flux;

[0108] Enter the step of determining the cross-sectional area of ​​the winding pole, the cross-sectional area of ​​the common magnetic yoke, and the cross-sectional area of ​​the decoupling magnetic yoke according to the maximum value of the magnetic flux.

[0109] In some embodiments, the process of determining the DC magnetic flux includes:

[0110] The DC flux is determined based on the number of turns of the winding wound on each phase winding column, the maximum DC bias current, the magnetic resistance of the upper common magnetic yoke, the magnetic resistance of the lower common magnetic yoke, the magnetic resistance of the decoupling magnetic yoke and the DC flux relationship. The DC flux relationship is: ;

[0111] Where R is the magnetic resistance of the winding column, R m is the magnetic resistance of each decoupling yoke, R m1 is the magnetic resistance of the upper common yoke and the lower common yoke, I dc is the maximum DC bias current, and L1 is the self-inductance of the first phase inductor.

[0112] According to the DC flux equivalent magnetic circuit diagram and the flux linkage formula, taking the first phase as an example, the DC flux Ф in the winding column and the ordinary magnetic yoke can be obtained. dc .

[0113] In some embodiments, the process of determining the self-inductance of the first phase inductor includes:

[0114] The self-inductance of each phase is determined based on the magnetic resistance of the winding rod, the magnetic resistance of each decoupling yoke, the magnetic resistance of the upper common yoke and the magnetic resistance of the lower common yoke. The expression of self-inductance is ;

[0115] Among them, L1 is the self-inductance of the first phase, L n is the self-inductance of the nth phase, R is the magnetic resistance of the winding column, R m is the magnetic resistance of each decoupling yoke, R m1 is the magnetic resistance of the upper common yoke and the lower common yoke.

[0116] N is the number of turns of the winding of each phase inductor. m1 and R m By using high magnetic permeability materials, the magnetic resistance can be equivalent to 0; in order to obtain the coupling coefficient between the first phase and the second phase, the magnetomotive force source other than the first phase can be set to zero. At this time, the magnetic flux Ф generated by the first phase winding current on the second phase 12 The expression is . Due to the magnetic resistance R of the lower common yoke m1 , the magnetic resistance R of the decoupling yoke m Much smaller than the magnetic resistance R of the winding column, let L1= L2=…= L n , so the coupling coefficient expression of the first phase and the second phase is Similarly, the coupling coefficient k between the inductors of each phase is approximately equal to 0, and the decoupling integrated inductor has a high degree of decoupling. The expression of each magnetic resistance is , where μ rao is the magnetic permeability of the winding pole magnetic material, l rao is the equivalent magnetic circuit length of each phase winding, S rao The cross-sectional area of ​​each phase winding column.

[0117] In some embodiments, determining the cross-sectional area of ​​the left winding leg of each phase and the cross-sectional area of ​​the right winding leg of each phase according to the maximum value of the magnetic flux includes:

[0118] The cross-sectional area of ​​each phase winding post on the XY plane is determined based on the maximum value of the magnetic flux and the maximum magnetic density of the winding post core material. The relationship between the cross-sectional area of ​​the winding post on the XY plane is: ;

[0119] Among them, Φ max is the maximum value of magnetic flux, B m1 is the maximum magnetic flux density of the winding core material, △Φ is the AC magnetic flux, L1 is the self-inductance of the first phase, I dc is the maximum DC bias current, V i is the input voltage of the converter, V o is the output voltage of the integrated inductor, D is the duty cycle, T s is the switching cycle.

[0120] In some embodiments, determining the cross-sectional area of ​​the common magnetic yoke according to the maximum value of the magnetic flux includes:

[0121] The cross-sectional area of ​​each phase common yoke on the YZ plane is determined based on the maximum value of the magnetic flux and the maximum magnetic density of the common yoke core material. The relationship between the cross-sectional area of ​​the common yoke on the YZ plane is: ;

[0122] Among them, Φ max is the maximum value of magnetic flux, B m2 is the maximum magnetic density of the common yoke core material, △Φ is the AC magnetic flux, L1 is the self-inductance of the first phase, I dc is the maximum DC bias current, V i is the input voltage of the integrated inductor, V o is the output voltage of the integrated inductor, D is the duty cycle, T s is the switching cycle.

[0123] Figure 9 A diagram showing the influence of different decoupling phase sequences on the peak magnetic flux on the decoupling yoke provided by the present invention;

[0124] In some embodiments, determining the cross-sectional area of ​​the decoupling yoke according to the maximum value of the magnetic flux includes:

[0125] Determine the maximum magnetic flux of the decoupling yoke;

[0126] The cross-sectional area of ​​the decoupling yoke on the YZ plane is determined according to the maximum magnetic flux. The expression of the cross-sectional area is: ;

[0127] Among them, Φ j1max is the maximum magnetic flux of the decoupling yoke, A ej1 To A ej(n-1) is the cross-sectional area of ​​the decoupling yoke on the YZ surface, V i is the input voltage of the integrated inductor, V o is the output voltage of the integrated inductor, D is the duty cycle, T s is the switching period, B m2 is the maximum magnetic flux density of the decoupling yoke core material.

[0128] The phase sequence of the decoupling integrated inductor needs to be determined. Different phase sequence arrangements will result in different peak magnetic flux on the decoupling yoke. Figure 10 The magnetic flux waveforms of the decoupling yoke are presented for four different decoupling phase sequences: first phase to second phase, first phase to third phase, first phase to fourth phase, and first phase to fifth phase. It can be seen that the decoupling effect is best achieved when the first and second phases are adjacent, resulting in the smallest peak magnetic flux of the decoupling yoke. This is because the flux waveforms of two adjacent phases are closest, resulting in the greatest degree of flux cancellation during decoupling, and the peak magnetic flux of the decoupling yoke is minimized. In this case, the cross-sectional area of ​​the decoupling yoke can be made smaller. Therefore, the optimal phase sequence for the decoupling integration of an n-phase interleaved parallel integrated inductor should be first phase, second phase, third phase, and so on, from top to bottom.

[0129] Taking the duty cycle D<1 / n as an example, Figure 10 is the n-phase inductor terminal voltage, n-phase inductor core magnetic flux, and the first decoupling magnetic yoke and the (n-1)th decoupling magnetic yoke magnetic flux waveform. L1 、u L2 …u Ln are the voltages across the first, second, and nth phase inductors, Φ1 is the magnetic flux of the upper common yoke and the left and right winding poles of the first phase, Φ2 is the magnetic flux of the left and right winding poles of the second phase, and Φ n is the magnetic flux of the lower common yoke and the left and right winding poles of the nth phase, Φ j1 is the magnetic flux of the first decoupling yoke, Φ j(n-1)is the magnetic flux of the (n-1)th decoupling yoke. Analysis Figure 10 It can be found that due to the canceling effect of the magnetic flux of the two adjacent phases at the decoupling yoke, the peak value of the magnetic flux of the decoupling yoke is smaller than that of the winding column. Therefore, the cross-sectional area of ​​the decoupling yoke on the YZ plane can be greatly reduced, thereby optimizing the volume of the integrated magnetic component.

[0130] From this, the maximum magnetic flux expression of (n-1) decoupling yokes can be obtained as follows: .

[0131] In some embodiments, determining the length of each phase winding post according to the number of turns of the winding, the maximum DC bias current of the integrated inductor, the equivalent magnetic path length of the winding post, and the equivalent magnetic path lengths of a common magnetic yoke and a decoupling magnetic yoke includes:

[0132] The maximum DC bias current is determined based on the number of turns of the winding, the magnetic field strength in the winding column, the magnetic field strength in the common yoke and the decoupling yoke, the equivalent magnetic path length of the winding column, and the equivalent magnetic path length of the common yoke and the decoupling yoke. The relationship between the maximum DC bias current is: ;

[0133] Among them, H1 is the magnetic field strength in the winding column, H2 is the magnetic field strength in the ordinary magnetic yoke and decoupling magnetic yoke, l eq1 is the equivalent magnetic circuit length of the winding column, l eq2 is the equivalent magnetic path length of the common yoke and the decoupling yoke, I dc is the maximum DC bias current;

[0134] Determine the relationship between the maximum magnetic flux density of the winding column and the maximum magnetic flux density and magnetic permeability of the ordinary magnetic yoke and the decoupling magnetic yoke. The expression for the relationship between the magnetic flux density, magnetic permeability and magnetic field strength is: ;

[0135] Among them, B m1 is the maximum magnetic density of the winding column, μ1 is the magnetic permeability of the winding column, B m2 is the maximum magnetic density of the common yoke and the decoupling yoke, μ2 is the magnetic permeability of the common yoke and the decoupling yoke;

[0136] Determine the magnetic resistance of the winding column based on the magnetic permeability;

[0137] The length of the winding post is determined by the magnetic resistance of the winding post.

[0138] If the winding column uses ferrite, the inductance can be adjusted by adjusting the size of the air gap. The larger the air gap, the lower the inductance, and the smaller the air gap, the higher the inductance.

[0139] When the winding column uses a magnetic material with low magnetic permeability, such as a powder core, if the inductance of each phase needs to be adjusted, it is necessary to adjust the length of the powder core to change the magnetic resistance of the winding column and thus adjust the inductance. Since the magnetic permeability of the powder core decreases as the DC bias current increases, it is necessary to meet the inductance requirements under the DC bias current. Assume that the function of the magnetic permeability of the powder core changing with the magnetic field strength H1 on it is , where %u i : The ratio of the powder core permeability to the initial permeability. a, b, and c are coefficients provided by the manufacturer. Assuming the magnetic field strength in the powder core winding rod is H1, and the magnetic field strength in the ordinary yoke and decoupled yoke is H2, the total current theorem yields: , where l eq1 is the equivalent magnetic path length of the winding core, l eq2 is the equivalent magnetic path length of the common yoke and the decoupling yoke, N is the number of winding turns of each phase inductance, I dc is the maximum DC bias current. The relationship between the maximum magnetic flux density, magnetic permeability, and magnetic field strength of the two core materials is: , where B m1 , μ1, H1 are the maximum magnetic density, magnetic permeability, and magnetic field strength in the winding column, B m2 , μ2, and H2 are the maximum magnetic flux density, magnetic permeability, and magnetic field strength of the standard and decoupled yokes. The above formula can be used to calculate the magnetic field strength in the winding post powder core, thereby determining the magnetic permeability of the winding post powder core at maximum bias current. This allows the reluctance of the winding post powder core to be calculated, and the length of the winding post powder core to be determined. If the inductance of each phase is too low, the equivalent reluctance of each phase needs to be reduced, which means reducing the length of the winding post. Repeated adjustments are made until the inductance of each phase meets the requirements at maximum bias current.

[0140] Figure 11 This is a structural schematic diagram of a design system for an integrated inductor provided by the present invention. The magnetic core of the integrated inductor includes an upper common yoke, a lower common yoke, a decoupling yoke, a winding post, and a winding. The winding post includes a left winding post and a right winding post. The first decoupling yoke to the n-1th decoupling yoke are sequentially arranged between the upper common yoke and the lower common yoke. The upper part of the i-th decoupling yoke is connected to the i-th phase left winding post and the i-th phase right winding post, and the lower part is connected to the i+1th phase left winding post and the i+1th phase right winding post. The upper common yoke is respectively connected to the first phase left winding post and the first phase right winding post, and the lower common yoke is respectively connected to the n-th phase left winding post and the n-th phase right winding post. Each phase left winding post and right winding post are wound with N / 2 turns of winding, 1<i<n, i and n are both integers. The design system of the integrated inductor includes:

[0141] An equivalent magnetic circuit determining unit 21 is configured to determine an equivalent magnetic circuit of the magnetic core according to the structure of the magnetic core of the integrated inductor;

[0142] a magnetic flux determination unit 22, configured to determine the magnetic flux of each phase in the magnetic core according to the equivalent magnetic circuit;

[0143] a cross-sectional area determining unit 23 for determining the cross-sectional area of ​​the winding post, the cross-sectional area of ​​the common magnetic yoke, and the cross-sectional area of ​​the decoupling magnetic yoke according to the maximum value of the magnetic flux;

[0144] a length determination unit 24 for determining the length of each phase winding post according to the number of turns of the winding, the maximum DC bias current of the integrated inductor, the equivalent magnetic path length of the winding post, and the equivalent magnetic path lengths of the common magnetic yoke and the decoupling magnetic yoke;

[0145] The size determination unit 25 is used to determine the size of the integrated inductor according to the cross-sectional area of ​​the winding post, the cross-sectional area of ​​the common magnetic yoke, the cross-sectional area of ​​the decoupling magnetic yoke, and the length of each phase winding post.

[0146] Based on the above embodiment:

[0147] The equivalent magnetic circuit determining unit 21 is specifically used to determine the equivalent magnetic circuit of the inductor according to the winding rod magnetic resistance, magnetomotive force, ordinary magnetic yoke magnetic resistance and decoupling magnetic yoke magnetic resistance.

[0148] The equivalent magnetic circuit determining unit 21 is specifically used to determine the equivalent magnetic circuit of the inductor according to the winding rod magnetic resistance, magnetomotive force, ordinary magnetic yoke magnetic resistance, decoupling magnetic yoke magnetic resistance and connection relationship;

[0149] The connection relationship includes the first end of the i-th decoupling yoke magnetic resistance being connected to the negative end of the i-th magnetomotive force and the first end of the i+1-th winding pole magnetic resistance, the positive end of the i-th magnetomotive force being connected to the first end of the i-th winding pole magnetic resistance, the second end of the i-th winding pole magnetic resistance being connected to the first end of the i-1-th decoupling yoke magnetic resistance, and the second end of the i-1-th decoupling yoke magnetic resistance being connected to the second end of the i-th decoupling yoke magnetic resistance; the first end of the first common magnetic yoke magnetic resistance being connected to the second end of the first winding pole magnetic resistance, the second end of the first common magnetic yoke magnetic resistance being connected to the second end of each decoupling yoke magnetic resistance and the second end of the second common magnetic yoke magnetic resistance, and the first end of the second common magnetic yoke magnetic resistance being connected to the negative end of the n-th magnetomotive force, where i is an integer greater than 1.

[0150] The magnetic flux determining unit 22 is specifically used to determine the magnetic flux of each decoupling yoke as the magnetic flux of the corresponding phase. The relationship between the magnetic flux of each phase is: ;

[0151] Where, Φ1(t) is the magnetic flux between the upper common yoke and the first phase winding column, Φ n (t) is the magnetic flux between the lower common yoke and the n-phase winding, Φ j1 (t) is the magnetic flux of the first decoupling yoke, Φ j(n-1) (t) is the magnetic flux of the n-1th decoupling yoke, i L1(t) is the current flowing through the first phase winding, i Ln (t) is the current flowing through the n-phase winding, and R is the magnetic resistance of the winding.

[0152] It also includes a magnetic flux maximum value determining unit for determining the maximum value of the magnetic flux. The expression of the maximum value of the magnetic flux is: ;

[0153] Among them, Φ max is the maximum value of magnetic flux, Φ dc is the DC magnetic flux, △Φ is the AC magnetic flux;

[0154] Enter the step of determining the cross-sectional area of ​​the winding pole, the cross-sectional area of ​​the common magnetic yoke, and the cross-sectional area of ​​the decoupling magnetic yoke according to the maximum value of the magnetic flux.

[0155] The process of determining DC flux includes:

[0156] The DC flux is determined based on the number of turns of the winding wound on each phase winding column, the maximum DC bias current, the magnetic resistance of the upper common magnetic yoke, the magnetic resistance of the lower common magnetic yoke, the magnetic resistance of the decoupling magnetic yoke and the DC flux relationship. The DC flux relationship is: ;

[0157] Where R is the magnetic resistance of the winding column, R m is the magnetic resistance of each decoupling yoke, R m1 is the magnetic resistance of the upper common yoke and the lower common yoke, I dc is the maximum DC bias current, and L1 is the self-inductance of the first phase.

[0158] The process of determining the self-inductance of the first phase includes:

[0159] The self-inductance of each phase is determined based on the magnetic resistance of the winding rod, the magnetic resistance of each decoupling yoke, the magnetic resistance of the upper common yoke and the magnetic resistance of the lower common yoke. The expression of self-inductance is ;

[0160] Among them, L1 is the self-inductance of the first phase, L n is the self-inductance of the nth phase, R is the magnetic resistance of the winding column, R m is the magnetic resistance of each decoupling yoke, R m1 is the magnetic resistance of the upper common yoke and the lower common yoke.

[0161] The cross-sectional area determining unit 23 is specifically used to determine the cross-sectional area of ​​each phase winding post on the XY plane according to the maximum value of the magnetic flux and the maximum magnetic density of the winding post core material. The relationship between the cross-sectional area of ​​the winding post on the XY plane is: ;

[0162] Among them, Φ max is the maximum value of magnetic flux, Bm1 is the maximum magnetic flux density of the winding core material, △Φ is the AC magnetic flux, L1 is the self-inductance of the first phase, I dc is the maximum DC bias current, V i is the input voltage of the integrated inductor, V o is the output voltage of the integrated inductor, D is the duty cycle, T s is the switching cycle.

[0163] The cross-sectional area of ​​each phase common yoke on the YZ plane is determined based on the maximum value of the magnetic flux and the maximum magnetic density of the common yoke core material. The relationship between the cross-sectional area of ​​the common yoke on the YZ plane is: ;

[0164] Among them, Φ max is the maximum value of magnetic flux, B m2 is the maximum magnetic density of the common yoke core material, △Φ is the AC magnetic flux, L1 is the self-inductance of the first phase, I dc is the maximum DC bias current, V i is the input voltage of the integrated inductor, V o is the output voltage of the integrated inductor, D is the duty cycle, T s is the switching cycle.

[0165] Determine the maximum magnetic flux of the decoupling yoke;

[0166] The cross-sectional area of ​​the decoupling yoke on the YZ plane is determined according to the maximum magnetic flux. The expression of the cross-sectional area is: ;

[0167] Among them, Φ j1max is the maximum magnetic flux of the decoupling yoke, A ej1 To A ej(n-1) is the cross-sectional area of ​​the decoupling yoke on the YZ surface, V i is the input voltage of the integrated inductor, V o is the output voltage of the integrated inductor, D is the duty cycle, T s is the switching period, B m2 is the maximum magnetic flux density of the decoupling yoke core material.

[0168] The length determination unit 24 is specifically configured to determine the maximum DC bias current based on the number of turns of the winding, the magnetic field strength in the winding post, the magnetic field strength in the common magnetic yoke and the decoupling magnetic yoke, the equivalent magnetic path length of the winding post, and the equivalent magnetic path length of the common magnetic yoke and the decoupling magnetic yoke. The relationship between the maximum DC bias current and the length is: ;

[0169] Among them, H1 is the magnetic field strength in the winding column, H2 is the magnetic field strength in the ordinary magnetic yoke and decoupling magnetic yoke, l eq1is the equivalent magnetic circuit length of the winding column, l eq2 is the equivalent magnetic path length of the common yoke and the decoupling yoke, I dc is the maximum DC bias current;

[0170] Determine the relationship between the maximum magnetic flux density of the winding column and the maximum magnetic flux density and magnetic permeability of the ordinary magnetic yoke and the decoupling magnetic yoke. The expression for the relationship between the magnetic flux density, magnetic permeability and magnetic field strength is: ;

[0171] Among them, B m1 is the maximum magnetic density of the winding column, μ1 is the magnetic permeability of the winding column, B m2 is the maximum magnetic density of the common yoke and the decoupling yoke, μ2 is the magnetic permeability of the common yoke and the decoupling yoke;

[0172] Determine the magnetic resistance of the winding column based on the magnetic permeability;

[0173] The length of the winding post is determined by the magnetic resistance of the winding post.

[0174] Figure 12 This is a schematic structural diagram of a design device for an integrated inductor provided by the present invention, the design device for an integrated inductor comprising:

[0175] Memory 31, for storing computer programs;

[0176] The processor 32 is configured to implement the steps of the above-mentioned integrated inductor design method when executing a computer program.

[0177] For an introduction to the design device for the integrated inductor provided in this application, please refer to the above embodiments, which will not be described in detail here.

[0178] Figure 2 This is a structural schematic diagram of an integrated inductor provided by the present invention. The magnetic core of the integrated inductor includes an upper common yoke, a lower common yoke, a decoupling yoke, a winding post and a winding. The winding post includes a left winding post and a right winding post. The first decoupling yoke to the n-1th decoupling yoke are sequentially arranged between the upper common yoke and the lower common yoke. The upper part of the i-th decoupling yoke is connected to the i-th phase left winding post and the i-th phase right winding post, and the lower part is connected to the i+1-th phase left winding post and the i+1-th phase right winding post. The upper common yoke is respectively connected to the first phase left winding post and the first phase right winding post, and the lower common yoke is respectively connected to the n-th phase left winding post and the n-th phase right winding post. N / 2 turns of winding are wound on the left winding post and the right winding post of each phase, 1<i<n, i and n are both integers.

[0179] This application discloses a design method for an n-phase, highly decoupled integrated inductor, addressing the cost, volume, and weight issues of existing n-phase power converters. The n-phase integrated inductor's magnetic core comprises two conventional yokes, (n-1) decoupling yokes, and 2n winding posts. The yokes are constructed from high-permeability magnetic materials, such as ferrite. The winding posts are constructed from low-permeability magnetic materials, such as powder core.

[0180] Figure 2 A front view of an n-phase staggered parallel integrated inductor provided by the present invention, Figure 5 A top view of an n-phase staggered parallel integrated inductor provided by the present invention, Figure 6 A side view of an n-phase staggered parallel integrated inductor provided by the present invention;

[0181] The N turns of winding for each phase are wound on the left and right winding poles, and the number of turns on the left and right winding poles is N / 2.

[0182] The left and right winding posts of the first phase can have air gaps with the upper common yoke and the first decoupling yoke. The left and right winding posts of the second phase can have air gaps with the first and second decoupling yokes. The left and right winding posts of the nth phase can have air gaps with the lower common yoke and the (n-1)th decoupling yoke. The first decoupling yoke is located between the first and second phase winding posts. The second decoupling yoke is located between the second and third phase winding posts. The (n-1)th decoupling yoke is located between the (n-1)th and nth phase winding posts. The Z-direction height of the (n-1) decoupling yokes is less than the Z-direction height of the two common yokes. The Y-direction depth of the two common yokes and the (n-1)th decoupling yoke is greater than the Y-direction depth of all winding posts. The core cross-sectional area of ​​the winding posts in the XY plane is less than the core cross-sectional area of ​​the two common yokes in the YZ plane.

[0183] For an introduction to the integrated inductor provided in this application, please refer to the above embodiments and will not be repeated here.

[0184] The present invention also provides a computer-readable storage medium having a computer program stored thereon. When the computer program is executed by a processor, the steps of the integrated inductor design method according to any one of claims 1 to 11 are implemented.

[0185] For an introduction to the computer-readable storage medium provided in this application, please refer to the above embodiments and will not be repeated here.

[0186] The various embodiments in this specification are described in a progressive manner, with each embodiment focusing on the differences from other embodiments. Reference can be made to the common and similar parts between the various embodiments. For the devices disclosed in the embodiments, since they correspond to the methods disclosed in the embodiments, the description is relatively simple, and the relevant parts can be referred to the method description.

[0187] It should also be noted that, in this specification, relational terms such as first and second, etc., are used only to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Moreover, the terms "comprises," "comprising," or any other variants thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus comprising a series of elements includes not only those elements, but also other elements not explicitly listed, or elements inherent to such process, method, article, or apparatus. In the absence of further limitations, an element defined by the phrase "comprising a ..." does not exclude the presence of additional identical elements in the process, method, article, or apparatus comprising the element.

[0188] Professionals may further appreciate that the units and algorithm steps of each example described in conjunction with the embodiments disclosed herein can be implemented in electronic hardware, computer software, or a combination of the two. In order to clearly illustrate the interchangeability of hardware and software, the above description has generally described the components and steps of each example according to their functions. Whether these functions are performed in hardware or software depends on the specific application and design constraints of the technical solution. Professionals and technicians may use different methods to implement the described functions for each specific application, but such implementation should not be considered beyond the scope of the present invention.

[0189] The steps of the methods or algorithms described in conjunction with the embodiments disclosed herein may be implemented directly using hardware, a software module executed by a processor, or a combination of the two. The software module may be placed in random access memory (RAM), internal memory, read-only memory (ROM), electrically programmable ROM, electrically erasable programmable ROM, registers, a hard disk, a removable disk, a CD-ROM, or any other form of storage medium known in the art.

[0190] The above description of the disclosed embodiments is intended to enable one skilled in the art to implement or use the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the present invention. Therefore, the present invention is not limited to the embodiments shown herein but is intended to conform to the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A design method for an integrated inductor, characterized in that: The magnetic core of the integrated inductor includes an upper common yoke, a lower common yoke, a decoupling yoke, a winding post and a winding, wherein the winding post includes a left winding post and a right winding post, and the first decoupling yoke to the n-1th decoupling yoke are sequentially arranged between the upper common yoke and the lower common yoke. The upper part of the i-th decoupling yoke is connected to the i-th phase left winding post and the i-th phase right winding post, and the lower part is connected to the i+1-th phase left winding post and the i+1-th phase right winding post. The upper common yoke is connected to the first phase left winding post and the first phase right winding post respectively, and the lower common yoke is connected to the n-th phase left winding post and the n-th phase right winding post respectively. N / 2 turns of winding are wound on the left winding post and the right winding post of each phase, 1<i<n, i and n are both integers, N is an even number, n is the total number of phases of the magnetic core of the integrated inductor, and N is the total number of turns of each phase winding; The design method of the integrated inductor includes: Determining an equivalent magnetic circuit of the magnetic core according to the structure of the magnetic core of the integrated inductor; determining the magnetic flux of each phase in the magnetic core according to the equivalent magnetic circuit; determining the cross-sectional area of ​​the winding column, the cross-sectional area of ​​the common magnetic yoke, and the cross-sectional area of ​​the decoupling magnetic yoke according to the maximum value of the magnetic flux; Determining the length of each phase winding post according to the number of turns of the winding, the maximum DC bias current of the integrated inductor, the equivalent magnetic path length of the winding post, and the equivalent magnetic path lengths of the common magnetic yoke and the decoupling magnetic yoke; The size of the integrated inductor is determined according to the cross-sectional area of ​​the winding post, the cross-sectional area of ​​the common magnetic yoke, the cross-sectional area of ​​the decoupling magnetic yoke, and the length of each phase winding post.

2. The method for designing an integrated inductor according to claim 1, wherein: Determining an equivalent magnetic circuit of the magnetic core according to the structure of the magnetic core of the integrated inductor includes: The magnetomotive force, winding rod reluctance, common yoke reluctance and decoupling yoke reluctance in the equivalent magnetic circuit of the magnetic core are determined according to the structure of the magnetic core of the integrated inductor.

3. The method for designing an integrated inductor according to claim 2, wherein: Determining the magnetomotive force, winding column reluctance, common yoke reluctance and decoupling yoke reluctance in the equivalent magnetic circuit of the magnetic core according to the structure of the magnetic core of the integrated inductor includes: Determining the connection relationship between the magnetomotive force, winding rod reluctance, common yoke reluctance and decoupling yoke reluctance in the equivalent magnetic circuit of the magnetic core according to the structure of the magnetic core of the integrated inductor; The connection relationship includes the first end of the i-th decoupling yoke magnetic resistance being connected to the negative end of the i-th magnetomotive force and the first end of the i+1-th winding post magnetic resistance, the positive end of the i-th magnetomotive force being connected to the first end of the i-th winding post magnetic resistance, the second end of the i-th winding post magnetic resistance being connected to the first end of the i-1-th decoupling yoke magnetic resistance, and the second end of the i-1-th decoupling yoke magnetic resistance being connected to the second end of the i-th decoupling yoke magnetic resistance; the first end of the first common magnetic yoke magnetic resistance being connected to the second end of the first winding post magnetic resistance, the second end of the first common magnetic yoke magnetic resistance being connected to the second end of each of the decoupling yoke magnetic resistances and the second end of the second common magnetic yoke magnetic resistance, and the first end of the second common magnetic yoke magnetic resistance being connected to the negative end of the n-th magnetomotive force, where i is an integer greater than 1.

4. The method for designing an integrated inductor according to claim 1, wherein: Determining the magnetic flux of each phase in the magnetic core according to the equivalent magnetic circuit includes: Determine the magnetic flux of each decoupling yoke. The relationship between the magnetic flux of each phase is: ; Where, Φ1(t) is the magnetic flux between the upper common yoke and the first phase winding column, Φ n (t) is the magnetic flux between the lower common yoke and the n-phase winding, Φ j1 (t) is the magnetic flux of the first decoupling yoke, Φ j(n-1) (t) is the magnetic flux of the n-1th decoupling yoke, i L1 (t) is the current flowing through the first phase winding, i Ln (t) is the current flowing through the n-phase winding, R is the magnetic resistance of the winding column, and t is the time variable.

5. The method for designing an integrated inductor according to claim 1, wherein: Before determining the cross-sectional area of ​​the winding column, the cross-sectional area of ​​the common magnetic yoke, and the cross-sectional area of ​​the decoupling magnetic yoke according to the maximum value of the magnetic flux, the method further includes: Determine the maximum value of the magnetic flux, the expression of the maximum value of the magnetic flux is ; Among them, Φ max is the maximum value of the magnetic flux, Φ dc is the DC magnetic flux, △Φ is the AC magnetic flux; The step of further determining the cross-sectional area of ​​the winding column, the cross-sectional area of ​​the common magnetic yoke and the cross-sectional area of ​​the decoupling magnetic yoke according to the maximum value of the magnetic flux.

6. The method for designing an integrated inductor according to claim 5, wherein: The process of determining the DC magnetic flux includes: The DC magnetic flux is determined according to the number of turns of the winding wound on each phase winding column, the maximum DC bias current, the magnetic resistance of the upper common magnetic yoke, the magnetic resistance of the lower common magnetic yoke, and the magnetic resistance of the decoupling magnetic yoke. The DC magnetic flux relationship is: ； Wherein, R is the magnetic resistance of the winding column, R m is the magnetic resistance of each decoupling yoke, R m1 is the magnetic resistance of the upper common yoke and the lower common yoke, I dc is the maximum DC bias current, and L1 is the self-inductance of the first phase inductor.

7. The method for designing an integrated inductor according to claim 6, wherein: The process of determining the self-inductance of the first phase inductor includes: The self-inductance of each phase is determined based on the magnetic resistance of the winding rod, the magnetic resistance of each decoupling magnetic yoke, the magnetic resistance of the upper common magnetic yoke and the magnetic resistance of the lower common magnetic yoke. The expression of the self-inductance is: ; Among them, L1 is the self-inductance of the first phase inductor, L n is the self-inductance of the first phase inductor, R is the magnetic resistance of the winding column, R m is the magnetic resistance of each decoupling yoke, R m1 is the magnetic resistance of the upper common yoke and the lower common yoke.

8. The method for designing an integrated inductor according to claim 1, wherein: Determining the cross-sectional area of ​​the winding column according to the maximum value of the magnetic flux includes: The cross-sectional area of ​​each phase of the winding post on the XY plane is determined according to the maximum value of the magnetic flux and the maximum magnetic density of the winding post core material. The relationship between the cross-sectional area of ​​the winding post on the XY plane is: ； Among them, Φ max is the maximum value of the magnetic flux, B m1 is the maximum magnetic density of the winding core material, △Φ is the AC magnetic flux, L1 is the self-inductance of the first phase inductor, I dc is the maximum DC bias current, V i is the input voltage of the integrated inductor, V o is the output voltage of the integrated inductor, D is the duty cycle, T s is the switching period, Φ dc is the DC magnetic flux, A e1 is the cross-sectional area of ​​the winding column on the XY plane.

9. The method for designing an integrated inductor according to claim 1, wherein: Determining the cross-sectional area of ​​the common magnetic yoke according to the maximum value of the magnetic flux includes: The cross-sectional area of ​​the common yoke on the YZ plane of each phase is determined according to the maximum value of the magnetic flux and the maximum magnetic density of the common yoke core material. The relationship formula of the cross-sectional area of ​​the common yoke on the YZ plane is: ； Among them, Φ max is the maximum value of the magnetic flux, B m2 is the maximum magnetic density of the common yoke core material, △Φ is the AC magnetic flux, L1 is the self-inductance of the first phase inductor, I dc is the maximum DC bias current, V i is the input voltage of the integrated inductor, V o is the output voltage of the integrated inductor, D is the duty cycle, T s is the switching period, Φ dc is the DC magnetic flux.

10. The method for designing an integrated inductor according to claim 1, wherein: Determining a cross-sectional area of ​​the decoupling magnetic yoke according to the maximum value of the magnetic flux includes: determining a maximum magnetic flux of the decoupling yoke; The cross-sectional area of ​​the decoupling yoke on the YZ plane is determined according to the maximum magnetic flux, and the expression of the cross-sectional area is: ； Among them, Φ j1max is the maximum magnetic flux of the decoupling yoke, A ej1 To A ej(n-1) is the cross-sectional area of ​​the decoupling yoke on the YZ surface, V i is the input voltage of the integrated inductor, V o is the output voltage of the integrated inductor, D is the duty cycle, T s is the switching period, B m2 is the maximum magnetic flux density of the decoupling yoke core material.

11. The method for designing an integrated inductor according to any one of claims 1 to 10, wherein: Determining the length of each phase winding post according to the number of turns of the winding, the maximum DC bias current of the integrated inductor, the equivalent magnetic path length of the winding post, and the equivalent magnetic path lengths of the common magnetic yoke and the decoupling magnetic yoke includes: The maximum DC bias current is determined according to the number of turns of the winding, the magnetic field strength in the winding post, the magnetic field strength in the common magnetic yoke and the decoupling magnetic yoke, the equivalent magnetic path length of the winding post, and the equivalent magnetic path length of the common magnetic yoke and the decoupling magnetic yoke. The relationship between the maximum DC bias current is: ; Wherein, H1 is the magnetic field strength in the winding column, H2 is the magnetic field strength in the common magnetic yoke and the decoupling magnetic yoke, l eq1 is the equivalent magnetic circuit length of the winding column, l eq2 is the equivalent magnetic path length of the common yoke and the decoupling yoke, I dc is the maximum DC bias current; Determine the relationship between the maximum magnetic flux density of the winding column and the maximum magnetic flux density and magnetic permeability of the ordinary magnetic yoke and the decoupling magnetic yoke. The expression for the relationship between the magnetic flux density, magnetic permeability and magnetic field strength is: ； Among them, B m1 is the maximum magnetic density of the winding column, μ1 is the magnetic permeability of the winding column, B m2 is the maximum magnetic density of the common magnetic yoke and the decoupling magnetic yoke, μ2 is the magnetic permeability of the common magnetic yoke and the decoupling magnetic yoke; determining the magnetic resistance of the winding bobbin based on the magnetic permeability; The length of the winding post is determined according to the magnetic resistance of the winding post.

12. A design system for an integrated inductor, characterized in that: The magnetic core of the integrated inductor includes an upper common yoke, a lower common yoke, a decoupling yoke, a winding post and a winding, wherein the winding post includes a left winding post and a right winding post, and the first decoupling yoke to the n-1th decoupling yoke are sequentially arranged between the upper common yoke and the lower common yoke. The upper part of the i-th decoupling yoke is connected to the i-th phase left winding post and the i-th phase right winding post, and the lower part is connected to the i+1th phase left winding post and the i+1th phase right winding post. The upper common yoke is connected to the first phase left winding post and the first phase right winding post respectively, and the lower common yoke is connected to the n-th phase left winding post and the n-th phase right winding post respectively. N / 2 turns of winding are wound on the left winding post and the right winding post of each phase, 1<i<n, i and n are both integers, n is the total number of phases of the magnetic core of the integrated inductor, and N is the total number of turns of each phase winding. The design system of the integrated inductor includes: an equivalent magnetic circuit determining unit, configured to determine an equivalent magnetic circuit of the magnetic core according to the structure of the magnetic core of the integrated inductor; a magnetic flux determining unit, configured to determine the magnetic flux of each phase in the magnetic core according to the equivalent magnetic circuit; a cross-sectional area determining unit, configured to determine the cross-sectional area of ​​the winding column, the cross-sectional area of ​​the common magnetic yoke, and the cross-sectional area of ​​the decoupling magnetic yoke according to the maximum value of the magnetic flux; a length determining unit, configured to determine the length of each phase winding post according to the number of turns of the winding, the maximum DC bias current of the integrated inductor, the equivalent magnetic path length of the winding post, and the equivalent magnetic path lengths of the common magnetic yoke and the decoupling magnetic yoke; A size determining unit is used to determine the size of the integrated inductor according to the cross-sectional area of ​​the winding post, the cross-sectional area of ​​the common magnetic yoke, the cross-sectional area of ​​the decoupling magnetic yoke, and the length of each phase winding post.

13. A design device for an integrated inductor, characterized in that: include: Memory for storing computer programs; A processor, configured to implement the steps of the method for designing an integrated inductor according to any one of claims 1 to 11 when executing the computer program.

14. An integrated inductor, characterized in that: The magnetic core of the integrated inductor includes an upper common yoke, a lower common yoke, a decoupling yoke, a winding post and a winding, wherein the winding post includes a left winding post and a right winding post, and the first decoupling yoke to the n-1th decoupling yoke are sequentially arranged between the upper common yoke and the lower common yoke. The upper part of the i-th decoupling yoke is connected to the i-th phase left winding post and the i-th phase right winding post, and the lower part is connected to the i+1-th phase left winding post and the i+1-th phase right winding post. The upper common yoke is respectively connected to the first phase left winding post and the first phase right winding post, and the lower common yoke is respectively connected to the n-th phase left winding post and the n-th phase right winding post. N / 2 turns of winding are wound on the left winding post and the right winding post of each phase, 1<i<n, i and n are both integers, n is the total number of phases of the magnetic core of the integrated inductor, and N is the total number of turns of each phase winding.

15. A computer-readable storage medium, characterized in that The computer-readable storage medium stores a computer program, which, when executed by a processor, implements the steps of the method for designing an integrated inductor according to any one of claims 1 to 11.

Images