A DC system saturated core fault current limiter (DCSFCL) was proposed to limit the fast rising trend of fault current in HVDC system. However, traditional method to calculate and design the DCSFCL tend to neglect leakage flux around the permanent magnet (PM), leading to large calculation error and inappropriate design procedure. The novel contribution of this paper is that it proposed a modularization method to analyze the permeance of both PM and adjacent air. Hence, the leakage flux effect is considered properly and a more accurate permeance matrix can be derived in a pure mathematical way. In this case, DCSFCL can be calculated much faster than the FEA simulation program with a promising accuracy regarding fault limiting performance. More importantly, design flow of the DCSFCL and related PM biased devices was given as well. Calculation result shows that inductance value calculated by the proposed method has less than 1% error compared with fine meshed FEA simulation result and about 20% increase in accuracy compared with traditional method that neglects PM leakage flux effect. Prototype of the DCSFCL was also built and experimental tests were carried out to verify the correctness of the proposed method.
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