A Multi-Permeability and Interleaved High-Frequency Magnetic Link With Advanced Soft-Magnetic Materials for Power Converter Applications

Advanced magnetic materials are widely used to design and develop high-power, high-frequency magnetic links (HFMLs) for power conversion systems. Multi-winding HFMLs (MWHFMLs) are increasingly used for grid-connected renewable energy systems (RESs). According to a research study, the majority of HFML topologies include non-interleaved windings and single permeability magnetic cores. As a result, the magnetic flux distributes unevenly in the cores, causing the magnetic material that is closer to the conductors to become saturated earlier than the magnetic material further away from the conductors. In this article, a novel design of a 25 kW, 20 kHz MWHFML for power converter considering multi-permeability core and interleaved winding topology is mathematically modeled and designed. The multi-permeability core-based HFML (MPCBHFML) is designed and analyzed using nanocrystalline 1K101 and 1K107B, and Metglas 2605SA1 materials. The electromagnetic properties of the proposed MPCBHFML are investigated and compared with the existing single-permeability core-based HFML (SPCBHFML). The proposed MPCBHFML offers less core saturation, low core loss, and higher power transfer due to its interleaved winding topology. Also, the inductance profile comparison shows more flattening with the proposed design compared to that of with existing design topology. An experimental prototype of a 5 kW MPCBHFML has been developed using 1K101, 1K107B, and 2605SA1 materials and tested at 20 kHz, 80 V to evaluate and compare the electromagnetic performance of the proposed MPCBHFML with that of the traditional SPCBHFML.