Article(id=1200394760893616877, tenantId=1146029695717560320, journalId=1189987059142926344, issueId=1200394757995360759, articleNumber=null, orderNo=null, doi=10.19457/j.1001-2095.dqcd24993, pmid=null, cstr=null, oa=null, hot=null, price=null, onlineType=0, articleFormat=0, articleType=null, articleTypeStr=research-article, receivedDate=1677513600000, receivedDateStr=2023-02-28, revisedDate=1678464000000, revisedDateStr=2023-03-11, acceptedDate=null, acceptedDateStr=null, onlineDate=1764126013253, onlineDateStr=2025-11-26, pubDate=1742400000000, pubDateStr=2025-03-20, doiRegisterDate=null, doiRegisterDateStr=null, onlineIssueDate=1764126013253, onlineIssueDateStr=2025-11-26, onlineJustAcceptDate=null, onlineJustAcceptDateStr=null, onlineFirstDate=null, onlineFirstDateStr=null, sourceXml=null, magXml=null, createTime=1764126013253, creator=13701087609, updateTime=1764126013253, updator=13701087609, issue=Issue{id=1200394757995360759, tenantId=1146029695717560320, journalId=1189987059142926344, year='2025', volume='55', issue='3', pageStart='3', pageEnd='96', issueExtLink='null', onlineDate='null', pubDate='null', beforeIssueId=null, nextIssueId=null, price=null, status=1, issueComplete=1, articleOrder=1, issueType=-1, specialIssue=null, createTime=1764126012562, creator=13701087609, updateTime=1764148644802, updator=13701087609, preIssue=null, nextIssue=null, ext={EN=IssueExt(id=1200489684553027930, tenantId=1146029695717560320, journalId=1189987059142926344, issueId=1200394757995360759, language=EN, specialIssueTitle=, coverIllustrator=null, specialIssueEditor=, specialIssueAbout=), CN=IssueExt(id=1200489684553027931, tenantId=1146029695717560320, journalId=1189987059142926344, issueId=1200394757995360759, language=CN, specialIssueTitle=, coverIllustrator=null, specialIssueEditor=, specialIssueAbout=)}, issueFiles=null}, startPage=27, endPage=34, ext={EN=ArticleExt(id=1200394761224966895, articleId=1200394760893616877, tenantId=1146029695717560320, journalId=1189987059142926344, language=EN, title=Analysis of Core Eddy Current Loss Caused by Leakage Flux in Nanocrystalline High-frequency Transformer, columnId=null, journalTitle=Electric Drive, columnName=null, runingTitle=null, highlight=null, articleAbstract=

High-frequency transformers are an essential component in series-resonant DC/DC converters,and their stable operation has a decisive impact on the reliability,efficiency,and power density of power supply systems. Nanocrystalline magnetic cores are widely used due to their advantages of high saturation magnetic flux,high magnetic permeability,low coercivity,and low high-frequency losses. In order to improve the power density of DC/DC converters,the leakage inductance of high-frequency transformers is commonly used as a resonant inductor to achieve the soft-switching characteristics of the switching devices. However,nanocrystalline alloys possess a high electrical conductivity,and when high-frequency leakage magnetic flux passes perpendicularly through the surface strip,it induces strong eddy currents,which could result in potential thermal issues,thereby compromising the stable and safe operation of the transformer and the system. An improved finite element simulation method for high-frequency transformers was proposed for determining the distribution characteristics of additional eddy current losses induced by high frequency leakage flux at large leakage inductance by building a three-dimensional model of nanocrystalline strips at the edge of the independent core,and its validity was verified by temperature rise experiments.

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高频变压器是串联谐振型DC/DC变换器中至关重要的组成部分,其稳定运行对于电源系统的可靠性、效率和功率密度都具有决定性的影响。纳米晶磁芯因其高饱和磁通、高磁导率、低矫顽力以及高频损耗低等优点而被广泛应用。为了提高DC/DC变换器的功率密度,高频变压器漏感被普遍用作谐振电感,以实现开关器件的软开关特性。然而,纳米晶合金具有较高的电导率,当高频漏磁通垂直穿过其表面带材时,将会感应出较强的涡流,从而引起潜在的热问题,这将对变压器及系统的稳定安全运行造成一定的影响。提出一种改进的高频变压器有限元仿真方法,通过建立独立的磁芯边缘纳米晶带材的三维模型,在漏感较大时,用于确定高频漏磁通感应时附加涡流损耗的分布特性,并用温升实验验证了其正确性。

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赵鲁(1984—),男,博士,副研究员,主要研究方向为大功率变流器及高性能电机牵引控制技术,Email:
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刘学(1996—),男,硕士研究生在读,主要研究方向为大功率电力电子,Email:

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Simulation results

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类型 漏感/μH 副边
电流/A
主磁芯
损耗/W
漏磁通涡流损耗/W 效率/%
绕组交叉 3.98 99.995 12.07 9.833 99.973
绕组分离 45.42 99.943 31.34 1 018.793 96.713
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仿真结果

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类型 漏感/μH 副边
电流/A
主磁芯
损耗/W
漏磁通涡流损耗/W 效率/%
绕组交叉 3.98 99.995 12.07 9.833 99.973
绕组分离 45.42 99.943 31.34 1 018.793 96.713
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纳米晶高频变压器漏磁通磁芯涡流损耗分析
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刘学 1, 2 , 赵鲁 1 , 马呈瑶 1, 2 , 范恩泽 1, 2 , 葛琼璇 1
电气传动 | 电力电子 2025,55(3): 27-34
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电气传动 | 电力电子 2025, 55(3): 27-34
纳米晶高频变压器漏磁通磁芯涡流损耗分析
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刘学1, 2 , 赵鲁1 , 马呈瑶1, 2, 范恩泽1, 2, 葛琼璇1
作者信息
  • 1 中国科学院 电工研究所,北京 100190
  • 2 中国科学院大学 电子电气与通信工程学院,北京 100049
  • 刘学(1996—),男,硕士研究生在读,主要研究方向为大功率电力电子,Email:

通讯作者:

赵鲁(1984—),男,博士,副研究员,主要研究方向为大功率变流器及高性能电机牵引控制技术,Email:
Analysis of Core Eddy Current Loss Caused by Leakage Flux in Nanocrystalline High-frequency Transformer
Xue LIU1, 2 , Lu ZHAO1 , Chengyao MA1, 2, Enze FAN1, 2, Qiongxuan GE1
Affiliations
  • 1 Institute of Electrical Engineering,Chinese Academy of Sciences,Beijing 100190,China
  • 2 School of Electronic,Electrical and Communication Engineering,University of Chinese Academy of Sciences,Beijing 100049,China
出版时间: 2025-03-20 doi: 10.19457/j.1001-2095.dqcd24993
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高频变压器是串联谐振型DC/DC变换器中至关重要的组成部分,其稳定运行对于电源系统的可靠性、效率和功率密度都具有决定性的影响。纳米晶磁芯因其高饱和磁通、高磁导率、低矫顽力以及高频损耗低等优点而被广泛应用。为了提高DC/DC变换器的功率密度,高频变压器漏感被普遍用作谐振电感,以实现开关器件的软开关特性。然而,纳米晶合金具有较高的电导率,当高频漏磁通垂直穿过其表面带材时,将会感应出较强的涡流,从而引起潜在的热问题,这将对变压器及系统的稳定安全运行造成一定的影响。提出一种改进的高频变压器有限元仿真方法,通过建立独立的磁芯边缘纳米晶带材的三维模型,在漏感较大时,用于确定高频漏磁通感应时附加涡流损耗的分布特性,并用温升实验验证了其正确性。

纳米晶磁芯  /  高频变压器  /  漏感  /  涡流损耗

High-frequency transformers are an essential component in series-resonant DC/DC converters,and their stable operation has a decisive impact on the reliability,efficiency,and power density of power supply systems. Nanocrystalline magnetic cores are widely used due to their advantages of high saturation magnetic flux,high magnetic permeability,low coercivity,and low high-frequency losses. In order to improve the power density of DC/DC converters,the leakage inductance of high-frequency transformers is commonly used as a resonant inductor to achieve the soft-switching characteristics of the switching devices. However,nanocrystalline alloys possess a high electrical conductivity,and when high-frequency leakage magnetic flux passes perpendicularly through the surface strip,it induces strong eddy currents,which could result in potential thermal issues,thereby compromising the stable and safe operation of the transformer and the system. An improved finite element simulation method for high-frequency transformers was proposed for determining the distribution characteristics of additional eddy current losses induced by high frequency leakage flux at large leakage inductance by building a three-dimensional model of nanocrystalline strips at the edge of the independent core,and its validity was verified by temperature rise experiments.

nanocrystalline core  /  high-frequency transformer  /  leakage inductance  /  eddy current loss
刘学, 赵鲁, 马呈瑶, 范恩泽, 葛琼璇. 纳米晶高频变压器漏磁通磁芯涡流损耗分析. 电气传动, 2025 , 55 (3) : 27 -34 . DOI: 10.19457/j.1001-2095.dqcd24993
Xue LIU, Lu ZHAO, Chengyao MA, Enze FAN, Qiongxuan GE. Analysis of Core Eddy Current Loss Caused by Leakage Flux in Nanocrystalline High-frequency Transformer[J]. Electric Drive, 2025 , 55 (3) : 27 -34 . DOI: 10.19457/j.1001-2095.dqcd24993
高频变压器是隔离型DC/DC变换器最重要的电气元件之一,承担着电压转换、能量传输和电气隔离等关键功能。高频变压器磁芯的体积、重量占 DC/DC 变换器的体积和重量的绝大部分,其性能对于整个功率传输系统至关重要。通过使用 SiC 等器件可以提高高频变压器的工作频率、降低其体积和重量,但是随着工作频率的提高,高频变压器磁芯损耗占比逐渐增高,这将导致磁芯内部温度升高,降低高频变压器的使用寿命,进而危及系统的稳定性。因此,对高频变压器的磁芯损耗进行研究具有重要意义。
目前,高频变压器磁芯损耗的计算主要采用损耗分离方法和经验公式两种方法。损耗分离方法对于损耗的计算比较准确,但因为计算过程涉及很多参数,并且各种损耗分离比较困难,造成参数的计算困难,因此在实际计算中很少采用。大多数研究学者普遍使用经验公式来模拟磁芯的损耗。经验模型可以快速计算磁芯损耗,最有名的模型是Steinmetz公式[1],此外,还有在 Steinmetz 公式的基础上,根据不同应用场景提出的修正的 Steinmetz 公式(modified Steinmetz equation,MSE)[2]、广义Steinmetz 公式(generalized Steinmetz equation,GSE)[3]、改进的广义 Steinmetz 公式(improved generalized Steinmetz equation,iGSE)[4]、波形系数 Steinmetz 公式(waveform-coefficient Steinmetz equation,WcSE)[5]、二次改进的广义 Steinmetz 公式(improved-improved generalized Steinmetz equation,i2GSE)[6]、 Steinmetz 公式的矩形扩展(rectangular extension of Steinmetz equation,RESE)[7]等经验模型。
高频变压器常用的磁芯材料包括硅钢片、铁氧体、非晶合金和纳米晶合金等,其性能各有优劣。纳米晶合金材料因其高饱和磁通、高磁导率、低矫顽力、高频损耗低以及高居里温度等优点,为电力电子仪器设备的小型化、轻量化提供了技术基础,被认为是高频大功率工况下综合性能最优的软磁材料[8-11]。文献[12]对硅钢片、非晶材料和纳米晶材料通过损耗分离模型进行评估,其实验结果表明,纳米晶材料的性能远高于硅钢片和非晶材料。文献[13]通过与多种铁氧体的比较,表明纳米晶具有更低的损耗密度、更高的磁通密度饱和度、更好的温度稳定性。纳米晶磁芯可由纳米晶带材绕制成圆环形,如图1所示。
纳米晶合金的高电导率使其在高频磁场下产生较强的涡流,存在潜在热问题。显然,在电导率不变的前提下,随着纳米晶带材厚度的减薄,涡流回路电阻增大,涡流损耗降低,因此,带材截面方向由时变的主磁通激发的涡流可以通过减小带材厚度来抑制。但是当漏感较大,即带材层法线方向的磁通较大时,无法有效降低该部分涡流回路的面积,故该方法效果不明显,仍会产生较高的局部涡流损耗,进而出现变压器过温的现象。这种情况下,磁芯温度分布不均匀[14],而涡流则会集中在漏磁通较大处[15],例如绕组汇合处,并且大部分涡流出现在带材的上、下两边。
大部分研究致力减小纳米晶高频变压器的漏磁通以抑制磁芯损耗,原、副边绕组完全交叉换位是有效方法[16-17]。然而,如果较大的漏感被集成到高频变压器中,就可以避免使用串联电感,从而减小变换器的体积和重量。
为了解决电感集成到高频变压器中的问题,相关学者进行了研究。文献[18]通过有限元分析和实验验证表明,在使用纳米晶磁芯时,绕组分开绕制所带来的漏感足以满足双有源桥变换器(dual active bridge,DAB)需要的移相电感。文献[19]使用高频SiC器件和纳米晶高频变压器,在DAB中将移相电感集成到高频变压器中,功率达到 16.7 kW。对于谐振型 DC/DC 变换器,则希望利用变压器足够大的漏感作为串联谐振电感,以实现开关器件的软开关特性,减小器件开关损耗,提升变换器功率密度[20-21]。对于开气隙的磁芯,气隙附近含有大量磁通垂直穿过纳米晶带材,其与漏磁通的损耗原理相似。文献[22]考虑到纳米晶材料的高电导率和气隙附近的漏磁通,提出带有边缘效应的修正Steinmetz 公式。文献[23]考虑变频特性和绕组弯曲效应的漏磁通计算式,用于实现漏电感的精确控制,低频下效果较好,并通过搭建频率为5 kHz的样机,实现了磁器件集成。纳米晶软磁材料本身具有高电导率,在穿过带材的漏磁通较大时,将不得不考虑高频漏感引起磁芯表面带材的附加涡流损耗,文献[24]通过亥姆霍兹方程与有限元仿真分析计算磁芯薄带在漏磁场下涡流损耗,表明该部分损耗占总损耗的大部分。文献[25]通过有限元仿真的方法表明,漏磁通较大处,涡流损耗越大,温升越高,甚至超过其居里温度。
目前鲜有学者研究无气隙纳米晶高频变压器漏磁通的涡流损耗。鉴于此,本文提出一种改进的高频变压器有限元仿真方法,该方法通过建立独立的磁芯边缘纳米晶带材的三维模型,以准确确定高频漏磁通感应时附加涡流损耗的分布特性,特别是在漏感较大的情况下。同时,本文还通过温升实验验证了该方法的有效性。
根据铁心损耗的机理,可以得到正弦激励下铁心损耗分离法的计算公式,假设磁滞损耗与频率成正比、涡流损耗与频率的平方成正比、剩余损耗与频率的 1.5 次方成正比,如下式[26]所示:
${P}_{\mathrm{v}}={C}_{\mathrm{h}}\cdot {B}_{\mathrm{m}}^{a}\cdot f+{C}_{\mathrm{c}\mathrm{e}}\cdot {B}_{\mathrm{m}}^{2}\cdot {f}^{2}+{C}_{\mathrm{e}\mathrm{x}}\cdot {B}_{\mathrm{m}}^{1.5}\cdot {f}^{1.5}  $
式中:Pv为单位体积下的磁芯损耗;ChCceCex分别为磁滞损耗系数、铁心涡流损耗系数、剩余损耗系数;f为激磁频率;a 为磁密指数;Bm为磁通密度的幅值。
损耗分离计算方法适用于低频工况,高频下误差较大。
经验模型中的Steinmetz 公式如下式所示:
${P}_{\mathrm{v}}=K\cdot {f}^{\alpha }\cdot {B}_{\mathrm{m}}^{\beta }$
式中:Kαβ为常数(称为 Steinmetz 参数),通过数据手册或曲线拟合获得。
对于纳米晶磁芯,以上两种方法可以计算主磁通在带材绕制面方向感应的涡流损耗,但是均没有考虑漏感带来的附加涡流损耗,仅在漏磁通较小或磁芯材料电阻率较大时适用,对于大功率且漏感较大的纳米晶高频变压器有较大误差。
在实际变压器中,初级绕组和次级绕组不能实现完全耦合。除了磁芯中完全通过两个绕组的主磁通之外,还有其他磁通在空气等介质中形成磁回路,漏感是这部分磁通的等效电感,输入到高频变压器的能量一部分被存储在漏磁场中。漏感的大小和分布与绕组布置有关,原边绕组和副边绕组彼此完全交叉可以增大耦合系数,从而降低漏感,相反,绕组完全分离可以增大漏感值。除此之外,漏感还与频率有关,因此漏感的设计对高频变压器的输出特性具有重要影响。
漏感可分为层间漏感Lσl、相间漏感Lσp和匝间漏感Lσt。对于本文所提的单层单相绕组,无层间漏感。匝间漏感相对较小,并且由于磁回路仅含有单匝线圈,磁回路的磁动势较小,其对外层纳米晶带材涡流不大,带来的漏磁通涡流损耗可忽略不计。因此,本文着重考虑相间漏感的影响。两相绕组分离时相间漏磁通如图2所示。
纳米晶高频变压器工作过程中,主磁通 Bp沿着纳米晶带材绕制方向分布,其在垂直 Bp平面内会感应出主磁通涡流 Jp,对于该部分涡流已有大量研究;漏磁通分布在空气和变压器结构件内,部分漏磁通 Bs 穿过带材平面而形成漏磁通涡流 Js,如图3所示。由于纳米晶合金为导电良导体,高频激励下磁芯内涡流由趋肤深度、薄带尺寸、磁场分布以及材料特性决定。
高频下漏磁通感应电流仍然具有趋肤效应,趋肤深度计算公式如下:
$\delta =\sqrt{2/\left(\omega \mu \gamma \right)}$
式中:$\delta $为趋肤深度,μm;ω为电角频率,rad/s;μ为磁导率,H/m;γ为电导率,S/m。
经过计算,本文所使用的纳米晶材料的趋肤深度约为16 μm,与带材厚度相近,因此,带材横截面上的涡流可不必考虑趋肤效应的影响。但是,磁芯尺寸远大于趋肤深度,因此,漏磁通涡流回路面积远大于带材厚度,该部分涡流并不会受到抑制。
在空间中,漏磁通分布不均,因此不同位置的纳米晶薄带涡流分布也不同。由图2可见,两相绕组彼此靠近处的漏磁通密度显著高于其他地方,根据法拉第电磁感应定律,漏磁通密度较高的区域将感应出较强的涡流,因此涡流损耗将集中于此区域。另外,由图3可见,在单层带材壁面的漏磁通涡流中,上、下两边电流密度远大于其他区域,所以其呈现出上、下对称且上、下两边的漏磁通涡流损耗远大于中部的漏磁通涡流损耗。温升可以反映涡流损耗的大小,因此原边绕组和副边绕组的两处线端交汇处的上、下两边将是主要的温升区域。
有限元方法可以直观地求解高频变压器的涡流损耗。一般来讲,纳米晶圆环磁芯由纳米晶带材卷绕而成,由于纳米晶带材极薄,厚度约为14~30 μm,卷绕深度少则几百层,多达几千层,并且由于制造工艺的限制,层与层之间通常有绝缘层,造成带材填充系数在0.7~0.9之间,因此使用三维有限元方法绘制真实的物理模型来计算磁芯损耗是不现实的。为了解决这个问题,此前学者通常使用2D模型来进行电磁仿真,然而,2D模型不能反映漏磁通在单层带材壁面上感应的涡流。目前大部分高频变压器3D模型未考虑纳米晶磁芯的制作工艺,仅将其视为一整块铁磁材料,因此在不考虑漏感的前提下,该方法可以满足工程需要,但是其无法求解本文考虑的外层涡流损耗。
图4为改进的实际变压器等效电路,其中,R1和R2为原边和副边侧的等效绕组电阻,Lσ1和Lσ2为原边和副边侧的等效漏感,Lm为励磁电感,Rm为产生传统铁心损耗的等效电阻,Re为产生漏磁通涡流损耗的等效电阻,本文着重考虑的部分。一般来讲,漏感和损耗等效电阻都是频变的。
ANSYS Maxwell 是业界著名的高精度电磁场模拟仿真软件,本文使用 Maxwell 3D 涡流场对纳米晶高频变压器进行仿真,得到了高频变压器的磁密分布和电密分布,以反映漏磁通涡流耗损。
首先,改进了纳米晶磁芯建模方法。在以往的模型中,磁芯被视为是一个整体。由于要考虑漏感的影响,漏磁通感应出来的涡流为环形电流,更深层的带材中涡流激发的磁感线会削弱较外部带材的磁通量,即一定程度上抑制了涡流的产生,因此,漏感感应的涡流主要集中在磁芯表面数层,所以,只需考虑磁芯边缘数层的漏磁通涡流损耗,较深处的涡流损耗可忽略不计。建模时,纳米晶圆环磁芯外部两侧用一组厚度接近真实带材厚度的同心圆代替。虽然纳米晶磁芯实际绕制时各层首尾相连,但是这种情况很难建模和网格剖分,与实际情况相比,宏观上两者仅在带材缠绕首尾处有不同,可忽略不计。磁芯内部绝大部分仍然为一整块实体,为了兼顾求解速度和精度,按照真实厚度在两侧表面各绘制10层带材,以观察磁场和涡流分布。
其次,改进了绕组建模方法。此前的研究中,由于漏感较小,并且其他磁芯材料(如铁氧体)无明显漏磁通涡流,因此大部分学者并未考虑绕组形状对漏感和磁芯损耗的影响,通常将原边绕组和副边绕组分别以一整块实体代替,以加快求解速度,求解结果在一定程度上可以接受,但是对于纳米晶软磁材料这样电导率较高且带材厚度极薄的磁芯材料,该方法误差较大。因此,本文在Maxwell 3D中建模时,按照实际的绕制方式绘制了绕组的形状。
最后,为了考察不同漏电感的损耗特性,采用两种绕组形式,即完全交叉换位和无交叉换位,如图5所示。原、副边绕组完全交叉时,只存在匝间漏感,如果原、副边绕组完全分离,相间漏感占绝大部分,此时漏磁通主要集中于两相绕组的汇合处附近,如图2所示。绕组多为利兹线,交流电阻较小,因此模型暂且不考虑绕组的高频交流损耗。绕组之间的距离也会影响漏感的大小,为了排除这部分因素,在绘制模型时,无论何种情况,相邻的单匝绕组之间的距离是一定的。
本文所使用的纳米晶磁芯主要参数为:外径200 mm,内径120 mm,高度50 mm,叠压系数0.8,带材实际厚度0.016 mm,带材层间隙0.004 mm,电导率769 230 S/m,磁芯磁滞损耗系数13.404,磁芯涡流损耗系数0.000 436 2,磁芯剩余损耗系数0。
纳米晶软磁材料BH曲线如图6所示。绘制模型时,为使模型总体积与所使用的磁芯相同,内部为一整块实体作为主磁芯,中间磁芯内径60.2 mm,外径99.8 mm,磁芯径向外部两侧表面各10层带材按照真实厚度绘制,磁芯截面如图7所示,两部分材料参数相同。利用 Maxwell 3D 涡流场分别求解如图5所示两种不同绕组结构的模型。仿真频率为40 kHz,原边激励为幅值100 A的正弦交流电,副边为6 Ω阻性负载。
为便于区分两部分损耗,主磁芯部分使用软件自带的磁芯损耗计算方法,利用磁芯各处磁密求解损耗;边缘的20层带材考虑涡流效应,使用感应涡流求解损耗。
对于绕组交叉和绕组分离两种情况,仿真结果如表1所示。从表1可知,绕组交叉时,漏感较小,绕组分离时,漏感较大,大约相差一个数量级。虽然绕组分离时主磁芯涡流损耗较大,但是仍然不能反映两者之间的差距。两侧共20层带材中漏磁通涡流损耗相差极大,约两个数量级,远高于主磁芯损耗,因此,漏感较大时,这部分损耗不可忽视。
各层带材的损耗曲线如图8所示,仿真验证了纳米晶高频变压器漏感越大,损耗越大。从图8中可以看出,涡流损耗随着带材层的深入逐渐降低。绕组交叉时,漏磁通涡流损耗远小于绕组分离时,并且随深度加深,下降趋势明显。绕组分离,即漏感较大时,下降趋势较为缓慢,说明漏磁通涡流损耗渗透深度随着漏感加大而加深。外侧的损耗比内侧损耗更大,说明外侧更容易发热严重,在进行变压器设计时,要考虑充分的散热措施。
绕组分离时,磁芯最外侧一层带材可以充分表明漏磁通涡流损耗。磁芯最外侧的带材感应磁通密度峰值如图9所示,数据范围均为0~4 T。从图中可以看出,如果绕组交叉,根据电流的磁效应,漏磁通较小且集中在某一单匝绕组附近;如果绕组分离,漏磁通会集中在相间漏感处,并且磁通极大。
磁芯最外侧的带材感应电流密度峰值如图10所示。两者数据分布范围均为0~4×107 A/m2。从图中可以看出,与图9类似,如果绕组分离,涡流集中在相间漏感处,即原边绕组和副边绕组分隔处,并且上、下两边的电流密度远大于中间。
漏磁通感应的涡流随纳米晶带材的深入而降低,图11展示了绕组分离时原、副边绕组靠近处的外侧带材电流密度,即图10中虚线内部。可以看出,电流密度随着深度的增加逐渐降低,内部的涡流由于趋肤效应集中在上、下两个边缘处。因此,漏磁通涡流损耗大部分在磁芯表面数层,磁芯内部带材受漏磁通影响越来越小。
为了验证漏磁通涡流的分布特性,在实物平台上进行了实验,搭建了一台漏感集成式串联谐振DC/DC变换器,如图12所示,各项参数为:原边支撑电容C1=1.2 mF,副边支撑电容C2=1.8 mF,漏感Lr=61.09 μH,谐振电容Cr=0.55 μF,死区时间Td=1 μs,变压器变比12∶12,负载电阻Rload=6 Ω,开关频率fs=36 kHz,控制频率fc=10 kHz,变压器初级绕组电阻Rp=15 mΩ,变压器次级绕组电阻Rs=15 mΩ。
原边绕组和副边绕组分离绕制,互不交叉,见图5b所示。输入输出电压均为200 V,控制方式为单移相控制,以TI公司的 TMS320F28335为主控芯片,开关器件采用型号为CAS300M12BM2的SiC MOSFET,使用热成像仪测量磁芯表面温度。
涡流损耗越大,则温度越高。自然风冷下,实验2 min后,磁芯温度如图13所示,最高温度超过120 ℃,温度分布与有限元仿真趋势相同,漏磁通涡流损耗导致的高温主要分布在磁芯两侧。径向来看,越靠近磁芯中部温度越低,磁芯内外两边缘温度最高;从最外侧圆周方向来看,原边绕组和副边绕组的线端交汇处漏磁通密度最大,此处温度最高,考虑到磁芯材料的传热特性,该处上、下两边的温度高于中部的温度,与仿真结果相同。
当系统稳定运行时,高频变压器原边电压、副边电压和原边电流波形如图14所示,原边电流相位滞后于原边电压,超前于副边电压,实现了软开关。但是磁芯温度较高,为系统安全运行带来了隐患,后续研究将着眼于降低漏磁通涡流损耗。
本文改进了纳米晶高频变压器有限元仿真方法,将磁芯边缘的10层带材独立建模,对比绕组交叉与绕组分离两种情况,确定了漏感较大时漏磁通涡流损耗的分布特性,即漏磁通涡流损耗主要集中在磁芯两侧边缘绕组交汇处的上、下两边,并通过磁芯温升实验验证了其正确性,对于漏电感集成式纳米晶高频变压器设计具有一定的参考意义。
  • 中国科学院青年创新促进会项目(2020146)
  • 北京市自然科学基金-丰台轨道交通前沿研究联合基金(L201005)
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doi: 10.19457/j.1001-2095.dqcd24993
  • 接收时间:2023-02-28
  • 首发时间:2025-11-26
  • 出版时间:2025-03-20
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  • 收稿日期:2023-02-28
  • 修回日期:2023-03-11
基金
中国科学院青年创新促进会项目(2020146)
北京市自然科学基金-丰台轨道交通前沿研究联合基金(L201005)
作者信息
    1 中国科学院 电工研究所,北京 100190
    2 中国科学院大学 电子电气与通信工程学院,北京 100049

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赵鲁(1984—),男,博士,副研究员,主要研究方向为大功率变流器及高性能电机牵引控制技术,Email:
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