Análise, modelagem e validação experimental de uma metodologia para o projeto do indutor em conversores Boost PFC

Abstract

This work presents the development of a methodology for design of inductor in singlephase PFC boost converters operating in CCM mode in agreement with international standards IEC 61000-3-2 and CISPR 22. Such converters are used in front-end modules of information technology equipment. This methodology is based on the investigation of the relationship among magnetic volume; switching frequency and input current ripple of the converter, presented in previous work and extended to allow the optimization of inductors with three magnetic materials: Kool Mμ, Molypermalloy and High-Flux. An analysis of some constructive characteristics of the inductors is performed, such as, magnetic materials and most appropriate type of winding, taking into account factors that can determine the lowest volume of the inductor, such as winding and magnetic losses, the flux density, and conducted electromagnetic interference (EMI). In construction of the inductors, it is discussed the use of single-layer winding, presenting their main haracteristics, advantages when seeking the reduction of conducted EMI, and considering the disadvantage of increasing of volume that this type winding may cause. An algorithm for this methodology is developed, that uses models able to estimate the differential mode conducted EMI for frequencies up to 30 MHz, as well the temperature rise of boost inductor by simulating the input current of the converter, considering soft saturation characteristics of magnetic materials and the use of commercial cores. Additionally, it is performed an experimental validation of the developed algorithm by construction of prototypes that uses three selected materials and operate at three different points of operation.