Optimization design method of magnetic shunt integrated inductor planar transformer and related device

Abstract

This invention discloses an optimized design method and related apparatus for a magnetic shunt integrated inductor planar transformer, comprising: designing the reluctance ratio parameter according to the effective turns ratio requirement. x Based on leakage inductance requirements and reluctance ratio parameters x Design a magnetic shunt reluctance R s Based on the requirements of the magnetizing inductance and the magnetic reluctance of the magnetic shunt... R s and reluctance ratio parameter x set up y / R g2 ,in, y It is the reluctance ratio coefficient. R g2 By using a lower core reluctance, this method and related devices can avoid problems such as effective turns ratio mismatch and excessive deviation between gain capability and design.

Description

Technical Field

[0001] This invention belongs to the field of power electronics technology DC / DC converters, and relates to an optimized design method and related device for a magnetic shunt integrated inductor planar transformer. Background Technology

[0002] The rapid development of technologies in various fields, such as electric vehicles and data centers, has placed increasingly higher demands on the efficiency and power density of power converters. LLC resonant converters, due to their ability to achieve soft switching and operate at higher frequencies, are considered a good choice for reducing the size of passive components. However, when facing wide voltage range requirements, LLC resonant converters require larger resonant inductors to achieve wide gain over a fixed frequency range. Larger resonant inductors mean larger size and losses, making the integration of the resonant inductor with the transformer a challenge.

[0003] To achieve the integration of multiple magnetic components in inductors and transformers, magnetic shunts have proven to be a theory that is easy to operate and has a wide integration range. By adding a magnetic shunt with a certain permeability at the location of high magnetomotive force between the primary and secondary windings, leakage inductance can be increased and controlled, thus achieving the integration of resonant inductors.

[0004] However, existing magnetic shunt structures only consider the increased leakage inductance introduced by the magnetic shunt to achieve the required gain for LLC converters. They lack a comprehensive analysis and solution to the problem of reduced effective turns ratio in the transformer model due to the decreased mutual inductance after adding the magnetic shunt. This leads to effective turns ratio mismatch and excessive deviations from the design gain in practical applications of magnetic shunt structures for leakage inductance integration, ultimately resulting in reduced converter efficiency or even inoperability. Summary of the Invention

[0005] The purpose of this invention is to overcome the shortcomings of the prior art and provide an optimized design method and related apparatus for a magnetic shunt integrated inductor planar transformer. This method and apparatus can avoid problems such as effective turns ratio mismatch and excessive deviation between gain capability and design.

[0006] To achieve the above objectives, this invention discloses an optimized design method for a magnetic shunt integrated inductor planar transformer, comprising: Design the reluctance ratio parameters according to the effective turns ratio requirement. x ; Based on leakage inductance requirements and magnetoresistive ratio parameters x Design a magnetic shunt reluctance R s ; Based on the requirements of the excitation inductance and the magnetic reluctance of the magnetic shunt R s and reluctance ratio parameter x set upy / R g2 ,in, y It is the reluctance ratio coefficient. R g2 The lower magnetic core reluctance.

[0007] Furthermore, R g1 = xR s ,in, R g1 The magnetic reluctance of the upper magnetic plate.

[0008] Furthermore, R g2 = yR g1 ,in, R g1 The magnetic reluctance of the upper magnetic plate.

[0009] Furthermore, by controlling the air length, an arbitrary equivalent permeability less than the actual permeability of the magnetic material in the magnetic shunt can be achieved.

[0010] Furthermore, the leakage inductance, magnetizing inductance, and effective turns ratio in resonant converter applications are as follows: .

[0011] This invention discloses an optimized design system for a magnetic shunt integrated inductor planar transformer, comprising: The first design module is used to design the reluctance ratio parameters according to the effective turns ratio requirement. x ; The second design module is used to determine the leakage inductance requirements and magnetoresistive ratio parameters. x Design a magnetic shunt reluctance R s ; The third design module is used to determine the requirements of the magnetizing inductance and the magnetic reluctance of the magnetic shunt. R s and reluctance ratio parameter x set up y / R g2 ,in, y It is the reluctance ratio coefficient. R g2 The lower magnetic core reluctance.

[0012] Furthermore, R g1 = xR s ,in, R g1 The magnetic reluctance of the upper magnetic plate.

[0013] Furthermore, R g2 = yR g1 ,in, R g1 The magnetic reluctance of the upper magnetic plate.

[0014] This invention discloses a computer device, including a memory, a processor, and a computer program stored in the memory and executable on the processor. When the processor executes the computer program, it implements the steps of the optimized design method for the magnetic shunt integrated inductor planar transformer.

[0015] This invention discloses a computer-readable storage medium storing a computer program, which, when executed by a processor, implements the steps of the optimized design method for the magnetic shunt integrated inductor planar transformer.

[0016] The present invention has the following beneficial effects: In practical operation, the optimized design method and related device of the magnetic shunt integrated inductor planar transformer described in this invention, based on the independent control of leakage inductance, magnetizing inductance and effective turns ratio, independently designs the reluctance ratio parameter, magnetic shunt reluctance and lower core reluctance respectively. Compared with the traditional method, under the same reluctance, the magnetic shunt material itself has reduced reluctance, and with the same material, it has a larger cross-sectional area and a smaller magnetic flux density, resulting in a higher saturation point and efficiency, avoiding the problems of effective turns ratio mismatch and excessive deviation between gain capability and design. Attached Figure Description

[0017] To more clearly illustrate the technical solutions of the embodiments of this application, the drawings used in the description of the embodiments of this application will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0018] Figure 1a This is a structural diagram of a traditional magnetic shunt integrated transformer; Figure 1b Comparison diagram of the structure and magnetic circuit of the integrated transformer for a three-variable independently controlled magnetic shunt; Figure 2 This invention presents the design structure of a magnetic shunt with arbitrary equivalent relative permeability. Figure 3 A finite element simulation model of the optimized structural design results is proposed for this invention; Figure 4 The prototype and comparison prototype used to verify this invention; Figure 5Simulation results of the integrated magnetic shunt transformer designed for this invention; Figure 6a For magnetic shunt reluctance R s Relationship diagram with dependent variable; Figure 6b For the upper magnetic core reluctance R g1 Relationship diagram with dependent variable; Figure 6c For the lower core reluctance R g2 Relationship diagram with dependent variable. Detailed Implementation

[0019] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0020] In the description of this invention, it should be understood that the terms "comprising" and "including" indicate the presence of the described features, integrals, steps, operations, elements and / or components, but do not exclude the presence or addition of one or more other features, integrals, steps, operations, elements, components and / or collections thereof.

[0021] It should also be understood that the terminology used in this specification is for the purpose of describing particular embodiments only and is not intended to limit the invention. As used in this specification and the appended claims, the singular forms “a,” “an,” and “the” are intended to include the plural forms unless the context clearly indicates otherwise.

[0022] It should also be further understood that the term "and / or" as used in this specification and the appended claims refers to any combination and all possible combinations of one or more of the associated listed items, and includes such combinations. For example, A and / or B can represent three cases: A alone, A and B simultaneously, and B alone. Additionally, the character " / " in this invention generally indicates that the preceding and following objects have an "or" relationship.

[0023] It should be understood that although terms such as first, second, third, etc., may be used in the embodiments of the present invention to describe the preset range, these preset ranges should not be limited to these terms. These terms are only used to distinguish the preset ranges from one another. For example, without departing from the scope of the embodiments of the present invention, the first preset range may also be referred to as the second preset range, and similarly, the second preset range may also be referred to as the first preset range.

[0024] Depending on the context, the word "if" as used here can be interpreted as "when," "when," "in response to determination," or "in response to detection." Similarly, depending on the context, the phrase "if determination" or "if detection (of the stated condition or event)" can be interpreted as "when determination," "in response to determination," "when detection (of the stated condition or event)," or "in response to detection (of the stated condition or event)."

[0025] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. The components of the embodiments of the present invention described and shown in the accompanying drawings can generally be arranged and designed in various different configurations. Therefore, the following detailed description of the embodiments of the present invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort are within the scope of protection of the present invention.

[0026] The accompanying drawings illustrate various structural schematic diagrams according to embodiments disclosed in this invention. These drawings are not to scale, and some details have been enlarged for clarity, and some details may have been omitted. The shapes of the various regions and layers shown in the drawings, as well as their relative sizes and positional relationships, are merely exemplary and may deviate from reality due to manufacturing tolerances or technical limitations. Furthermore, those skilled in the art can design regions / layers with different shapes, sizes, and relative positions as needed.

[0027] Example 1 In the embodiment, with V in =40-60 V, V o =12 V, P =120 W, L k =0.76 μH, L m =2.4 μH, N Using a parameter ratio of 5:2 as a case study, the principle analysis and structural design of the proposed magnetic shunt structure that simultaneously optimizes the effective turns ratio, leakage inductance, and magnetizing inductance are performed, proving that it conforms to theory and has sufficient industrial value.

[0028] This invention is to Figure 1aThe conventional magnetic shunt structure shown features independently controllable air gaps in its upper and lower sections. Since the lower air gap is independent of the turns ratio and leakage inductance, and only related to the magnetizing inductance, the overall design achieves control and optimization of leakage inductance, magnetizing inductance, and effective turns ratio. Typically, core symmetry can reduce EMI; however, this pair is horizontally symmetrical. Because the number of turns and current on the primary and secondary sides are different, the vertically symmetrical air gaps in the conventional structure are physically meaningless. Therefore, the proposed structure does not introduce additional EMI problems.

[0029] like Figure 2 As shown, based on the magnetic circuit characteristics and the superposition theorem, the three magnetic fluxes shown in the figure are solved. φ 1. φ 2. φ 3 is:

[0030]

[0031]

[0032] Based on the transformer circuit mutual inductance model and Ampere's law, the self-inductance, mutual inductance, and secondary self-inductance of the circuit are obtained as follows:

[0033] To facilitate variable analysis, let R g1 = xR s , R g2 = yR g1 Based on the two-port equivalent of the transformer, the mutual inductance model is transformed into a single leakage inductance model, yielding the leakage inductance, magnetizing inductance, and effective turns ratio for resonant converter applications as follows:

[0034] The results demonstrate that the proposed structure can achieve independent control of leakage inductance, magnetizing inductance, and effective turns ratio. In the embodiment section, based on the parameters of the embodiment, it is set... N p =3, N s =1, and the relevant results for the proposed structure are as follows:

[0035] Based on the above analysis, the optimized design method of the magnetic shunt integrated inductor planar transformer of the present invention includes the following steps: 1) Design the reluctance ratio parameters based on the effective turns ratio requirement. x； From the expression for the effective turns ratio, it can be seen that the effective turns ratio is only related to the ratio of the reluctance of the upper core to the reluctance of the shunt. Therefore, the effective turns ratio is used to determine... x In the following steps, it is only necessary to ensure that x If the ratio of the magnetic core reluctance to the magnetic shunt reluctance remains unchanged, the effective turns ratio of the magnetic components can be guaranteed to be the required turns ratio.

[0036] In this embodiment, to achieve an effective turns ratio of 2.5, x =0.1, meaning that the magnetic reluctance of half of the magnetic shunt is 10 times that of the upper magnetic core.

[0037] 2) Based on leakage inductance requirements and reluctance ratio parameters x Design a magnetic shunt reluctance R s ; When the reluctance ratio coefficient x When the value is constant, the leakage inductance is only related to the magnetic reluctance of the magnetic shunt. R s Relatedly, therefore, by designing the magnetic reluctance of the magnetic shunt... R s To achieve the leakage inductance requirement, in this embodiment, L k =0.76 μH, therefore the magnetic reluctance of the magnetic shunt is R s for:

[0038] when R s and x Once confirmed, due to R g1 = xR s Therefore, the magnetic reluctance of the upper magnetic plate R g1 Sure.

[0039] 3) Based on the requirements of the excitation inductance and the magnetic reluctance of the magnetic shunt R s and reluctance ratio parameter x set up y / R g2 ; When the reluctance ratio coefficient x And magnetic shunt magnetic reluctance R s When the value is constant, the magnetizing inductance is only related to the reluctance ratio coefficient. y Relatedly, due to the magnetic reluctance of the upper magnetic plate R g1 It has been determined, combined R g2 = yRg1 y and the magnetic reluctance of the lower core R g2 Fully relevant, therefore through design y / R g2 To achieve the required magnetizing inductance. In this embodiment, L m =2.33 μH, therefore the reluctance ratio can be calculated directly.

[0040] Based on the above three steps, the design can be realized by using the proposed magnetic shunt integrated structure to convert the resonant inductance, effective turns ratio and excitation inductance of the circuit parameters into three parts of magnetic reluctance in the physical structure of the magnetic core.

[0041] The reluctance of the upper and lower magnetic cores can be adjusted simply by changing the air gap in the middle column, provided the overall core remains unsaturated. However, the reluctance design of a magnetic shunt remains relatively complex. On one hand, in simulations, the reluctance of a magnetic shunt is typically achieved by adjusting the permeability and thickness to create arbitrary reluctance. However, in practice, the range of low-permeability magnetic materials is relatively limited, and only discrete permeabilities are available, restricting the application of magnetic shunts. On the other hand, magnetic shunts are usually thin, and when a certain inductance value is achieved, the magnetic flux flowing through them is large, potentially leading to saturation issues. For example... Figure 3 As shown, this invention connects the air reluctance and the magnetic reluctance of the magnetic shunt in series to achieve the total magnetic reluctance of the magnetic shunt. By adjusting the lengths of the magnetic shunt and the air, an arbitrary relative permeability lower than the magnetic permeability of the magnetic shunt can be achieved. Assuming that the relative permeability of the magnetic shunt corresponding to the required Rs magnetic reluctance is:

[0042] Based on such Figure 3 As shown, the magnetic reluctance of the magnetic shunt is:

[0043] The relationship between air permeability and magnetic shunt permeability was calculated separately, and the relationship between relative permeability was obtained as follows:

[0044] in, l = l air + l shunt It can be clearly seen that by controlling the lengths of the two parts, any value greater than 1 and less than 1 can be achieved. μ s The relative permeability.

[0045] Example 2 To verify the feasibility and relationship of the proposed integrated magnetic shunt structure, a corresponding integrated magnetic shunt transformer was designed based on this invention. The design parameters are shown in Table 1. The core material and the magnetic shunt material are DMR53 and FS100 from Dongci Company, respectively. The air gaps between the upper and lower cores are gap1 and gap2, respectively. Table 1

[0046] The results were verified by building simulation and experimental prototypes. The simulation model is as follows: Figure 3 As shown, the experimental prototype with proposed structure and comparison of independent inductor structure is as follows: Figure 4 As shown. Due to the integration of a resonant inductor, the converter's footprint is reduced by 22%, significantly improving power density and efficiency.

[0047] The simulated magnetic flux density and current density are as follows: Figure 5 As shown, the magnetic shunt has the highest magnetic flux density due to its small cross-sectional area. However, due to the use of this invention, the highest magnetic flux density is 0.2 T. The material is not saturated, the primary and secondary current densities are normally distributed, and the transformer works normally.

[0048] To verify the correctness of this invention, the relationship between the three independent variables and the dependent variable was traversed and statistically analyzed in the simulation. The relationship between the three independent reluctances and the effective turns ratio, leakage inductance, and magnetizing inductance was adjusted independently, as follows: Figure 6a , Figure 6b and Figure 6c As shown in the image. It can be seen that reducing the magnetic reluctance of the magnetic shunt... R s The leakage inductance increases significantly, while the magnetizing inductance and turns ratio decrease; the upper core reluctance is increased. R g1 The magnetizing inductance, leakage inductance, and effective turns ratio are all reduced; the lower core reluctance is increased. R g2 With the leakage inductance and effective turns ratio remaining unchanged, the magnetizing inductance decreases. The above conclusions are consistent with the theory, proving that the structural theory proposed in this invention is correct and has wide value in industrial applications.

[0049] Example 3 This invention discloses an optimized design system for a magnetic shunt integrated inductor planar transformer, comprising: The first design module is used to design the reluctance ratio parameters according to the effective turns ratio requirement. x ; The second design module is used to determine the leakage inductance requirements and magnetoresistive ratio parameters. x Design a magnetic shunt reluctance R s ; The third design module is used to determine the requirements of the magnetizing inductance and the magnetic reluctance of the magnetic shunt. Rs and reluctance ratio parameter x set up y / R g2 ,in, y It is the reluctance ratio coefficient. R g2 The lower magnetic core reluctance.

[0050] In this embodiment, R g1 = xR s ,in, R g1 The magnetic reluctance of the upper magnetic plate.

[0051] In this embodiment, R g2 = yR g1 ,in, R g1 The magnetic reluctance of the upper magnetic plate.

[0052] The module division in this embodiment is illustrative and represents only one logical functional division. In actual implementation, other division methods may be used. Furthermore, the functional modules in each embodiment of this application can be integrated into a single processor, exist as separate physical entities, or be integrated into a single module. The integrated modules described above can be implemented in hardware or as software functional modules.

[0053] Example 4 A computer device includes a memory, a processor, and a computer program stored in the memory and executable on the processor. When the processor executes the computer program, it implements steps of an optimization method for the magnetic shunt integrated inductor planar transformer, for example, including: designing reluctance ratio parameters based on effective turns ratio requirements. x Based on leakage inductance requirements and reluctance ratio parameters x Design a magnetic shunt reluctance R s Based on the requirements of the magnetizing inductance and the magnetic reluctance of the magnetic shunt... R s and reluctance ratio parameter x set up y / R g2 ,in, y It is the reluctance ratio coefficient. R g2The lower magnetic core magnetoresistive element is used. The memory may include main memory, such as high-speed random access memory (RAM), or it may also include non-volatile memory, such as at least one disk storage device. The processor, network interface, and memory are interconnected via an internal bus, which can be an industry-standard architecture bus, a peripheral component interconnection standard bus, or an extended industry-standard architecture bus. The bus can be categorized as an address bus, data bus, and control bus. The memory stores programs; specifically, the program may include program code, which includes computer operation instructions. The memory may include main memory and non-volatile memory, and provides instructions and data to the processor.

[0054] Example 5 A computer-readable storage medium storing a computer program, which, when executed by a processor, implements steps for optimizing the design of the magnetic shunt integrated inductor planar transformer, including, for example, designing reluctance ratio parameters based on effective turns ratio requirements. x Based on leakage inductance requirements and reluctance ratio parameters x Design a magnetic shunt reluctance R s Based on the requirements of the magnetizing inductance and the magnetic reluctance of the magnetic shunt... R s and reluctance ratio parameter x set up y / R g2 ,in, y It is the reluctance ratio coefficient. R g2 The lower magnetic core magnetoresistive element is used. Specifically, the computer-readable storage medium includes, but is not limited to, volatile memory and / or non-volatile memory. The volatile memory may include random access memory (RAM) and / or cache memory, etc. The non-volatile memory may include read-only memory (ROM), hard disk, flash memory, optical disk, magnetic disk, etc.

[0055] Those skilled in the art will understand that embodiments of this application can be provided as methods, systems, or computer program products. Therefore, this application can take the form of a completely hardware embodiment, a completely software embodiment, or an embodiment combining software and hardware aspects. Furthermore, this application can take the form of a computer program product embodied on one or more computer-usable storage media (including but not limited to disk storage, CD-ROM, optical storage, etc.) containing computer-usable program code.

[0056] This application is described with reference to flowchart illustrations and / or block diagrams of methods, apparatus (systems), and computer program products according to embodiments of this application. It will be understood that each block of the flowchart illustrations and / or block diagrams, and combinations of blocks in the flowchart illustrations and / or block diagrams, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, special-purpose computer, embedded processor, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, create means for implementing the functions specified in one or more blocks of the flowchart illustrations and / or one or more blocks of the block diagrams.

[0057] These computer program instructions may also be stored in a computer-readable storage medium that can direct a computer or other programmable data processing device to function in a particular manner, such that the instructions stored in the computer-readable storage medium produce an article of manufacture including instruction means that implement the functions specified in one or more flowcharts and / or one or more block diagrams.

[0058] These computer program instructions may also be loaded onto a computer or other programmable data processing apparatus to cause a series of operational steps to be performed on the computer or other programmable apparatus to produce a computer-implemented process, such that the instructions, which execute on the computer or other programmable apparatus, provide steps for implementing the functions specified in one or more flowcharts and / or one or more block diagrams.

[0059] Other embodiments of the invention will readily occur to those skilled in the art upon consideration of the specification and disclosure of the invention. This application is intended to cover any variations, uses, or adaptations of the invention that follow the general principles of the invention and include common knowledge or customary techniques in the art not disclosed herein. The specification and examples are to be considered exemplary only, and the true scope and spirit of the invention are indicated by the following claims.

[0060] It should be understood that the present invention is not limited to the precise structure described above and shown in the accompanying drawings, and various modifications and changes can be made without departing from its scope. The scope of the invention is limited only by the appended claims.

[0061] The above description is merely a preferred embodiment of the present invention and does not constitute any limitation on the present invention. Any simple modifications, alterations, or equivalent structural changes made to the above embodiments based on the technical essence of the present invention shall still fall within the protection scope of the present invention.

Claims

1. An optimized design method for a magnetic shunt integrated inductor planar transformer, characterized in that, include: Design the reluctance ratio parameters according to the effective turns ratio requirement. x ; Based on leakage inductance requirements and magnetoresistive ratio parameters x Design a magnetic shunt reluctance R s ; Based on the requirements of the excitation inductance and the magnetic reluctance of the magnetic shunt R s and reluctance ratio parameter x set up y / R g2 ,in, y It is the reluctance ratio coefficient. R g2 The lower magnetic core reluctance.

2. The optimized design method for the magnetic shunt integrated inductor planar transformer according to claim 1, characterized in that, R g1 = xR s ,in, R g1 The magnetic reluctance of the upper magnetic plate.

3. The optimized design method for the magnetic shunt integrated inductor planar transformer according to claim 1, characterized in that, R g2 = yR g1 ,in, R g1 The magnetic reluctance of the upper magnetic plate.

4. The optimized design method for the magnetic shunt integrated inductor planar transformer according to claim 1, characterized in that, By controlling the air length, any equivalent permeability less than the actual permeability of the magnetic material in the magnetic shunt can be achieved.

5. The optimized design method for the magnetic shunt integrated inductor planar transformer according to claim 1, characterized in that, Leakage inductance, magnetizing inductance, and effective turns ratio in resonant converter applications: 。 6. An optimized design system for a magnetic shunt integrated inductor planar transformer, characterized in that, include: The first design module is used to design the reluctance ratio parameters according to the effective turns ratio requirement. x ; The second design module is used to determine the leakage inductance requirements and magnetoresistive ratio parameters. x Design a magnetic shunt reluctance R s ; The third design module is used to determine the requirements of the magnetizing inductance and the magnetic reluctance of the magnetic shunt. R s and reluctance ratio parameter x set up y / R g2 ,in, y It is the reluctance ratio coefficient. R g2 The lower magnetic core reluctance.

7. The optimized design system for the magnetic shunt integrated inductor planar transformer according to claim 6, characterized in that, R g1 = xR s ,in, R g1 The magnetic reluctance of the upper magnetic plate.

8. The optimized design system for the magnetic shunt integrated inductor planar transformer according to claim 6, characterized in that, R g2 = yR g1 ,in, R g1 The magnetic reluctance of the upper magnetic plate.

9. A computer device comprising a memory, a processor, and a computer program stored in the memory and executable on the processor, characterized in that, When the processor executes the computer program, it implements the steps of the optimized design method for the magnetic shunt integrated inductor planar transformer as described in any one of claims 1-5.

10. A computer-readable storage medium storing a computer program, characterized in that, When the computer program is executed by the processor, it implements the steps of the optimized design method for the magnetic shunt integrated inductor planar transformer as described in any one of claims 1-5.

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