高频LLC谐振变换器的磁集成和一体化PCB绕组优化设计  

Optimal Design of Integrated Magnetics and PCB Winding for High-frequency LLC Resonant Converter

作　　者：刘越 纪国盛 邹军 吴红飞[1] 杨元 郭跃东 LIU Yue;JI Guosheng;ZOU Jun;WU Hongfei;YANG Yuan;GUO Yuedong(Automation College,Nanjing University of Aeronautics and Astronautics,Nanjing 210006,Jiangsu,China)

机构地区：[1]南京航空航天大学自动化学院,江苏南京210006

出　　处：《电气传动》2023年第2期24-31,共8页Electric Drive

基　　金：国家自然科学基金(52122708);江苏省自然科学基金(BK20200017);南京航空航天大学跨学科创新基金(KXKCXJJ202206)。

摘　　要：研究了一种基于磁集成技术和一体化PCB绕组的高频高密度LLC谐振变换器的优化设计与实现方式。LLC谐振变换器的变压器与谐振电感被集成在一个磁芯中,通过将谐振电感配置在变压器副边以实现两个磁件之间更大的磁通相位差。有限元仿真结果表明,相比于分立磁件,集成磁件的体积降低了12%,磁芯损耗降低了23%。此外,为了减小PCB绕组层间电容引起共模噪声,研究了一种针对全桥整流电路的对称一体化PCB绕组实现方式,部分屏蔽层绕组集成为原边绕组以提高绕组利用率。最后,搭建了一台1.2 MHz-750 W-270 V/48 V的LLC谐振变换器,峰值效率达96.6%,功率密度达44 W/mm^(3),共模电流的对比测试结果也验证了所研究的一体化PCB绕组的有效性。The optimal design of the magnetic integration and integrated printed circuit board(PCB)winding based on a high-frequency high-density LLC resonant converter was studied. Both the transformer and resonant inductor were integrated into only one magnetic core. By configuring the resonant inductor on the secondary side of the transformer,larger phase difference can be achieved. According to the finite element analysis(FEA)simulation results,compared with the separate cores,the volume is 12% lower and the core loss is 23% lower after integration. In addition,to reduce the common-mode(CM)noise,a symmetrical integrated PCB winding for full-bridge rectifier was proposed. Part of the shielding windings worked as the primary winding to improve the winding utilization.Finally,a 1.2 MHz-750 W-270 V/48 V LLC resonant converter was built with a peak efficiency of 96.6% and the power density of 44 W/mm^(3). The comparison test results of the CM current also prove the effectiveness of the proposed integrated PCB winding structure.

关 键 词：LLC谐振变换器 矩阵变压器 PCB绕组 屏蔽层 磁集成 

分 类 号：TM28[一般工业技术—材料科学与工程]