Design Methodology of Single and Multi-Winding Coupled Inductor in Switching Converters

Abstract

Efficient design of power converters rely on the performance of its inbuilt elements like inductor, capacitor, resistor, switches, power supply etc. An optimum design of its elements proves the effective operation of the system. In this manuscript, Kg method of designing magnetic element such as filter inductor with specified flux density and attained copper loss is proposed. In order to achieve the necessary inductance, avoid saturation and achieve an appropriate low copper loss and dc resistance, the core’s effective electrical size, or Kg, is measured. Design procedure involves selection of a core and then calculating air gap, turns and conductor size. The method is also extended to multi winding element in converter applications which results in the optimal conductor dimensions of the windings to minimize the overall winding loss. Total copper loss has been shown to be minimised when the window area is allocated between the windings according to their apparent powers.