Abstract
Evaluating the high-frequency winding loss accurately is crucial for the design of modern high-frequency power converters. This paper proposes a novel experimental method to accurately measure the in-situ inductor winding loss, which separates out the winding loss from the core loss through the reactive voltage cancellation concept. The proposed in-situ measurement can account for the complete winding loss including impacts from non-ideal field distributions by testing the inductor with the core attached, e.g., the winding edge effect, bypass flux, fringing flux, and the non-linear dynamic behaviour of the core, which cannot be well modelled with the existing analytical or simulation methods. This method has immunity against the probe phase discrepancy error, since it is designed to measure a pair of voltage and current that are in phase. This approach can be considered as the first attempt of applying the reactive voltage cancellation concept in measuring winding loss, while this concept was originally brought up for core loss and applied for core loss measurement only. By performing a Triple Pulse Test (TPT) procedure, the winding losses under practical large signals with dc-bias and rectangular voltage can be evaluated with the proposed testing circuit. The proposed approach is compared and verified against the conventional methods relying on ( <xref ref-type="disp-formula" rid="deqn1" xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink">1</xref> ) small-signal impedance measurements and FFT analysis ( <xref ref-type="disp-formula" rid="deqn2-deqn3" xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink">2</xref> ) in-situ measurement with the two winding method to exclude the core loss. The presented method provides a foundation for the accurate in-situ evaluation of winding loss covering all the large-signal and non-linear effects.
Highlights
Along with the advances of high-switching-frequency power converters, the winding loss of the magnetic components makes considerable impacts on the converter efficiency and temperature rise
Given passive components normally account for around 30%–50% of the total volume/weight of a typical power electronics system, how to accurately model/evaluate the high-frequency loss of magnetic components is critical for the precise design of the system
PROPOSED IN-SITU WINDING LOSS MEASUREMENT METHOD This paper proposes a testing circuit in Fig. 2 to accurately measure the winding loss, which is inspired by the reactive voltage cancellation concept [15], [22], [26]–[27] and the twowinding method for core loss measurement
Summary
Along with the advances of high-switching-frequency power converters, the winding loss of the magnetic components makes considerable impacts on the converter efficiency and temperature rise. The impedance analyzer has limitations in capturing the winding loss (RAC) in the case with high amplitudes/dc-bias, high frequency as well as high-Q inductors The other inductive reactive voltage cancellation methods for core loss measurement cannot match the IUT magnetizing inductance value as accurate as the proposed method, because they utilize air-cored inductors with a large number of windings to reach the matching inductance, which can lead to significant parasitic components and subsequently significant error of measurement [22], [26]–[27], [34]–[36]. Considering the mismatch between the RT and IUT, the magnetizing inductance is more influential and the core loss is less of an issue, while both of them can be relatively minimized in the proposed approach as a result of requiring the same device
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