Automated tool for 3D planar magnetic temperature modelling: application to EE and E/PLT core-based components

International audienceThermal performance of power converters is a key issue for the power integration. Temperatures inside active and passive devices can be determined using thermal models. Modelling the temperature distribution of high frequency magnetic components is quite complex due to diversity of their geometries and used materials. This paper presents a thermal modelling method based on lumped elements thermal network model, applied to planar magnetic components made of EE and E/PLT cores. The 3D model is automatically generated from the component's geometry. The computation enables to obtain 3D temperature distribution inside windings and core of planar transformers or inductors, in steady state or in transient case. The paper details the proposed modelling method as well as the automated tool including the problem definition and the solving process. The obtained temperature distributions are compared with Finite Element simulation results and measurements on different planar transformers

Design of a Low-Capacitance Planar Transformer for a 4 kW/500 kHz DAB Converter

International audienceIncreasing electrification in transport sectors, from automotive to aerospace, highlights the need for low size and high power density components. The recent advent of planar technology theoretically allows to reduce considerably the size of the magnetic components. This article focuses on the design of a high frequency planar transformer intended to be used in a 4 kW 500 kHz DAB converter. In particular, the inter-winding capacitances are assessed, as they have a strong influence on the behaviour of the DAB, and in some extreme cases may impede operation entirely. Analytical and finite element models are used to evaluate the stray elements of the transformer (resistance of the conductors, inter-winding capacitance and leakage inductance), and the resulting circuit model is compared with experimental measurements. This work focuses on influences of design parameters on the transformer stray elements

Modeling and design of planar trasnformers for embedded DC/DC power converter

Ces travaux de thèse s’inscrivent dans la problématique de développement de transformateurs planar pour l’intégration de puissance, dans le contexte de l’avion plus électrique (More Electric Aircraft – MEA) où les contraintes de volume et de poids sont primordiales. Les composants magnétiques restent en effet un frein à l’intégration des systèmes d’Electronique de Puissance et les composants planar (transformateurs et inductances) offrent une alternative intéressante aux composants bobinés pour la réduction de la taille des convertisseurs.Dans ce manuscrit, des méthodes, un outil de dimensionnement et des prototypes de transformateurs planar (2 et 3 enroulements) en technologie feuillard et PCB sont développés pour des applications de convertisseur DC/DC aéronautique. Dans un premier temps, les modèles permettant le calcul des pertes, l'estimation de l'élévation de température et le calcul de l’inductance de fuite sont présentés et comparés afin de concevoir des outils de calculs pour la conception. Dans un deuxième temps, il est montré que la modification de la forme des angles des spires rectangulaires permet de réduire significativement les pertes cuivre HF. Sur la base de ces outils et résultats, des prototypes de transformateurs planar à 3 enroulements en PCB multicouches sont développés. De nombreux prototypes sont caractérisés et valident les modèles de dimensionnement proposés. Enfin, l’un de ces prototypes est intégré et testé dans un convertisseur de puissance DC/DC de 3.75kW mettant en évidence les gains obtenus.These thesis works deal with the issue of the planar transformers development for power integration, in the context of the More Electric Aircraft (MEA), where the constraints of volume and weight are paramount. Magnetic components remain a hindrance to the integration of Power Electronics systems and planar components (transformers and inductors) offer an interesting alternative to wound components for reducing the size of converters.In these works, methods, a sizing tool and prototypes of planar transformers (2 and 3 windings) in strip and PCB technology are developed for aeronautical DC / DC converter applications. Firstly, the models allowing the calculation of the losses, the estimation of the temperature rise and the calculation of the leakage inductance are presented and compared in order to design calculation tools for engineers. In a second step, it is shown that the modification of the shape of the angles of rectangular turns makes it possible to significantly reduce the HF copper losses.Based on these tools and results, prototypes of 3-windings planar transformers in multilayer PCBs are developed. Many prototypes are characterized and validate the proposed designing models. Finally, one of these prototypes is integrated and tested in a DC / DC power converter of 3.75kW highlighting the gains obtained

Modélisaton et conception de transformateurs planar pour convertisseur de puissance DC/DC embarqué

These thesis works deal with the issue of the planar transformers development for power integration, in the context of the More Electric Aircraft (MEA), where the constraints of volume and weight are paramount. Magnetic components remain a hindrance to the integration of Power Electronics systems and planar components (transformers and inductors) offer an interesting alternative to wound components for reducing the size of converters.In these works, methods, a sizing tool and prototypes of planar transformers (2 and 3 windings) in strip and PCB technology are developed for aeronautical DC / DC converter applications. Firstly, the models allowing the calculation of the losses, the estimation of the temperature rise and the calculation of the leakage inductance are presented and compared in order to design calculation tools for engineers. In a second step, it is shown that the modification of the shape of the angles of rectangular turns makes it possible to significantly reduce the HF copper losses.Based on these tools and results, prototypes of 3-windings planar transformers in multilayer PCBs are developed. Many prototypes are characterized and validate the proposed designing models. Finally, one of these prototypes is integrated and tested in a DC / DC power converter of 3.75kW highlighting the gains obtained.Ces travaux de thèse s’inscrivent dans la problématique de développement de transformateurs planar pour l’intégration de puissance, dans le contexte de l’avion plus électrique (More Electric Aircraft – MEA) où les contraintes de volume et de poids sont primordiales. Les composants magnétiques restent en effet un frein à l’intégration des systèmes d’Electronique de Puissance et les composants planar (transformateurs et inductances) offrent une alternative intéressante aux composants bobinés pour la réduction de la taille des convertisseurs.Dans ce manuscrit, des méthodes, un outil de dimensionnement et des prototypes de transformateurs planar (2 et 3 enroulements) en technologie feuillard et PCB sont développés pour des applications de convertisseur DC/DC aéronautique. Dans un premier temps, les modèles permettant le calcul des pertes, l'estimation de l'élévation de température et le calcul de l’inductance de fuite sont présentés et comparés afin de concevoir des outils de calculs pour la conception. Dans un deuxième temps, il est montré que la modification de la forme des angles des spires rectangulaires permet de réduire significativement les pertes cuivre HF. Sur la base de ces outils et résultats, des prototypes de transformateurs planar à 3 enroulements en PCB multicouches sont développés. De nombreux prototypes sont caractérisés et valident les modèles de dimensionnement proposés. Enfin, l’un de ces prototypes est intégré et testé dans un convertisseur de puissance DC/DC de 3.75kW mettant en évidence les gains obtenus

Modélisaton et conception de transformateurs planar pour convertisseur de puissance DC/DC embarqué

These thesis works deal with the issue of the planar transformers development for power integration, in the context of the More Electric Aircraft (MEA), where the constraints of volume and weight are paramount. Magnetic components remain a hindrance to the integration of Power Electronics systems and planar components (transformers and inductors) offer an interesting alternative to wound components for reducing the size of converters.In these works, methods, a sizing tool and prototypes of planar transformers (2 and 3 windings) in strip and PCB technology are developed for aeronautical DC / DC converter applications. Firstly, the models allowing the calculation of the losses, the estimation of the temperature rise and the calculation of the leakage inductance are presented and compared in order to design calculation tools for engineers. In a second step, it is shown that the modification of the shape of the angles of rectangular turns makes it possible to significantly reduce the HF copper losses.Based on these tools and results, prototypes of 3-windings planar transformers in multilayer PCBs are developed. Many prototypes are characterized and validate the proposed designing models. Finally, one of these prototypes is integrated and tested in a DC / DC power converter of 3.75kW highlighting the gains obtained.Ces travaux de thèse s’inscrivent dans la problématique de développement de transformateurs planar pour l’intégration de puissance, dans le contexte de l’avion plus électrique (More Electric Aircraft – MEA) où les contraintes de volume et de poids sont primordiales. Les composants magnétiques restent en effet un frein à l’intégration des systèmes d’Electronique de Puissance et les composants planar (transformateurs et inductances) offrent une alternative intéressante aux composants bobinés pour la réduction de la taille des convertisseurs.Dans ce manuscrit, des méthodes, un outil de dimensionnement et des prototypes de transformateurs planar (2 et 3 enroulements) en technologie feuillard et PCB sont développés pour des applications de convertisseur DC/DC aéronautique. Dans un premier temps, les modèles permettant le calcul des pertes, l'estimation de l'élévation de température et le calcul de l’inductance de fuite sont présentés et comparés afin de concevoir des outils de calculs pour la conception. Dans un deuxième temps, il est montré que la modification de la forme des angles des spires rectangulaires permet de réduire significativement les pertes cuivre HF. Sur la base de ces outils et résultats, des prototypes de transformateurs planar à 3 enroulements en PCB multicouches sont développés. De nombreux prototypes sont caractérisés et valident les modèles de dimensionnement proposés. Enfin, l’un de ces prototypes est intégré et testé dans un convertisseur de puissance DC/DC de 3.75kW mettant en évidence les gains obtenus

Pre-sizing of a modular high power density DC/DC converter with GaN components

International audienceFinding the most appropriate architecture to achieve a function is a major engineering challenge. In the power conversion context, the question that arises is: what is the best trade-off between an architecture based on a single high-power converter and another based on the combination of multiple low-power converters? This article aims to answer this question in the specific case of the isolated interface between the low voltage (28 VDC) and high voltage (±270 VDC) buses of an aircraft. Towards this goal, the targeted power electronics converter is carefully modelled in order to obtain an accurate and fast computing model. A technological database of the different usable components is then used to feed an optimization algorithm. The execution of the latter achieves an attractive and robust result showing an excellent performance in terms of power-to-weight ratio, which is the key index of this study. The precision and speed of this computer-aided design is based on analytical models that are quick to run and therefore enable exploring almost exhaustively the search space. More specifically, the high-frequency transformer has a large relative mass and generates significant losses that are difficult to assess. A major modeling effort has been undertaken and has enable to define a simplified but convincing and accurate model (successfully assessed on a wide bandwidth using an experimental setup). It was used for the first time in this optimization process. According to the targeted aeronautical specifications, the two best solutions would make it possible to achieve a mass power density of 4.5 kW/kg, i.e. twice as high as traditional solutions. This result very clearly shows that the appropriate use of the new GaN transistors makes it possible to make a technological breakthrough. Considering the voltage and current ratings of these components, this shows that the combination of multiple partial converters is very promising and will make it possible in the future to achieve a significant increase in the compactness of electrical power conversion functions. This sizing study therefore clearly shows the potential of the standardized design of power electronics converters and the search for the best combinations (series, parallel) to meet any specific specifications. Additionnaly, the developed approach, based on a modelling effort, especially as far as the high-frequency transformer is concerned, and collection of manufacturer data, also makes it possible to limit the implementations and associated tests. Hence, the main contributions of this article are i) the assembly of the analytical models of the various components constituting an isolated DC-DC power supply, ii) the simplification of an analytical model of the planar HF transformer, its experimental validation and its first use in a loop of optimization, iii) the fact of showing supporting figures that GaN technology enables technological breakthroughs to achieve high power density, which opens the way to modular architectures based on partial converters of electrical power, iv) the comprehensive description of a powerful pre-study design tool enabling to greatly reduce power converters' time to market

Conception of High-Frequency Power Planar Transformer Prototypes Based on FabLab Platform

Conceiving planar magnetic components for power electronic converters is very constraining, especially in the case of prototype development. Indeed, such making requires skills, specific appliances as well as human time for setting up the machine tools and the fabrication process. With the emergence of Fabrication Laboratory (FabLab), conceiving of planar copper foil prototypes becomes more feasible in a shortened time process for engineers and researchers. This paper presents a methodology and process for conceiving power planar transformers with the help of machines and tools that can be found in the usual FabLab

Prototypage rapide de transformateurs planar

International audienceLa conception rapide de prototypes de laboratoire est intéressante pour permettre la validation, à moindre frais, de dimensionnements spécifiques de transformateurs planar. Avec l’apparition des Fabrication Laboratory (FabLab), il devient possible, en utilisant les outils et machines disponibles dans ces derniers, de réaliser de manière assez simple, rapide et peu coûteuse, des prototypes de transformateur planar en technologie feuillard. Cet article présente donc une méthodologie permettant de concevoir ce type de composant, pour des puissances de quelques kilowatts, en utilisant le matériel usuel des FabLab

AC Resistance and Leakage Inductance Estimation for Planar Transformers With Parallel-Connected Windings

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Planar Magnetic Components in More Electric Aircraft: Review of Technology and Key Parameters for DC–DC Power Electronic Converter

International audienceThe More Electric Aircraft (MEA) has motivated aircraft manufacturers since few decades. Indeed, their investigations lead to the increase of electric power in airplanes. The challenge is to decrease the weight of embedded systems and therefore the fuel consumption. This is possible thanks to new efficient power electronic converters made of new components. As magnetic components represent a great proportion of their weight, planar components are an interesting solution to increase the power density of some switching mode power supplies. This paper presents the benefits and drawbacks of high frequency planar transformers in DC/DC converter, different models developed for their design and different issues in MEA context related to planar's specific geometry and technology