Design Methodology of High Power Density Converter with Wide Input Voltage Range

High-power density and high efficiency have always been the pursuit of power supplies. In the industry, the two-stage converter is widely employed in various applications for its inherent advantages, such as high reliability and simple control. In this article, the design methodology of high-power-d...

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Bibliographic Details
Published in:IEEE transactions on industrial electronics (1982) 2025-01, Vol.72 (1), p.419-429
Main Authors: Wang, Pinhe, Zsurzsan, Tiberiu-Gabriel, Andersen, Michael A. E., Ouyang, Ziwei
Format: Article
Language:English
Subjects:
Configuration management
Coupled inductors
Design engineering
Energy conversion efficiency
Inductors
Magnetic cores
magnetic integration
Magnetic resonance
Magnetic switching
Topology
topology comparison
transformer
Transformers
two-stage converter
wide input voltage range
Windings
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Summary:High-power density and high efficiency have always been the pursuit of power supplies. In the industry, the two-stage converter is widely employed in various applications for its inherent advantages, such as high reliability and simple control. In this article, the design methodology of high-power-density converters is given and presented for the two-stage converters systematically, including topology comparison, magnetic integration, and circuit parameters design. First, this article evaluates and compares three different topologies and the Boost-DCX configuration with low-component stress factors is selected. Then, to shrink the magnetic size, a matrix core is proposed to integrate two coupled inductors and one transformer. In comparison with the traditional magnetic design method using two E-I cores, the footprint of proposed core is reduced by around 30%. Finally, the proposed methodology is employed in a two-stage isolated converter for datacenter applications. A 1-kW prototype, from 38-72-V input to 53.5-V output, demonstrates a peak efficiency of 95.6% and a power density of 126 W/in 3 .
ISSN:0278-0046
1557-9948
DOI:10.1109/TIE.2024.3413834