Coupled-Inductors Losses Modelling for Size and Weight Optimization Process Avoiding Time-Consuming Co-Simulations

Abstract:
The multiphase interleaved power converters with coupled-inductors structure interest more and more power electronics and in particular the Electric Vehicles (EV) market. This configuration leads to reduce the size of inductors and filters and thus, increase the power electronic density in comparison with non-coupled inductors. To take advantage of the inductors coupling and optimize the converter’s weight and volume, it is important to estimate total core and copper losses. This paper deals with a 60 kW Four-phases interleaved boost converter based on SiC MOSFET. This converter is intended to be used in an automotive application where downsizing and efficiency are strongly required. For this purposes, an approximation model for copper loss is proposed whilst avoiding co-simulations during the optimization process. Concerning the core loss estimation, a comparative study between the different frequency models and the loss obtained using 3D Finite Element calculations allows us to choose the most suitable one to be used in the optimization process.