IES Chapter Webinar on " Coupled Finite Element Simulations and Magnetic Design for Power Electronics: Approaches and Applications "

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Overview

The webinar "Coupled Finite Element Simulations and Magnetic Design for Power Electronics: Approaches and Applications" provided attendees with a comprehensive understanding of the role of electromagnetic devices in power electronics, with a particular emphasis on using the Finite Element Method (FEM) for the simulation and design of critical components like transformers and rotating machines. The event, hosted virtually, attracted 33 participants, including 28 IEEE members and 4 non-members, consisting of professionals and academics interested in power electronics and magnetic design.

Dr. Sai Ram from IIT Dharwad led the session, focusing on the significance of FEM in optimizing performance during the early design stages, considering physical factors such as temperature and mechanical stress. The webinar also explored accurate circuit modeling, material selection, and performance optimization of magnetic components in power electronics systems.

Key Topics Covered:

1. Magnetic Materials in Power Electronics

• Skin Depth and Frequency: Dr. Sai Ram explained how operating frequency affects skin depth, influencing material selection for magnetic cores. Materials like FESI with high-saturation flux density were highlighted as optimal choices for reducing core size and improving efficiency.

• Permeability and Temperature: The speaker discussed how permeability changes with frequency and temperature, particularly in materials like ferrites and nanocrystalline alloys, and the impact of these variations on no-load current and copper losses.

2. Transformer Design and Material Selection

• Core Loss and Efficiency: The importance of using materials with high-saturation flux density to achieve compact and efficient transformers was covered, though the higher costs of such materials remain a limiting factor.

• Weight Reduction: Optimizing core geometry and magnetic coupling is critical for reducing transformer size and weight, which is particularly beneficial in electric vehicle applications.

3. Winding Design and AC Resistance

• Skin and Proximity Effects: At high frequencies, skin and proximity effects increase AC resistance. To mitigate these effects, the use of multi-strand conductors was recommended, along with calculating AC resistance factors using Dover’s expression.

4. Magnetic Integration in Power Converters

• Ripple Current Reduction: Coupled inductors were shown to improve converter performance by increasing effective inductance, thereby reducing ripple current.

• Core and Copper Loss Reduction: Integration of inductors reduces both core volume and copper losses, improving thermal efficiency and overall system performance.

5. Gate Drive Circuits for Silicon Carbide (SiC) MOSFETs

• The use of low-leakage pulse transformers (PTs) to improve gate waveforms, reduce switching losses, and enhance system stability in high-frequency applications involving SiC-based systems was highlighted.

6. Magnetic Materials for Resonant Converters and Induction Heating

• For resonant converters used in induction heating, high-saturation, high-permeability materials with low core loss and high thermal conductivity were emphasized as key to improving system efficiency and thermal management.

 

Key Takeaways:

1. Material Selection: High-performance materials like ferrites and nanocrystalline alloys improve efficiency and minimize losses, but require balancing cost and application needs.

2. Magnetic Integration: The integration of coupled inductors in power converters enhances performance by reducing losses and improving thermal efficiency.

3. Winding Design: Proper winding design is essential for minimizing skin and proximity effects in high-frequency applications, which directly affects AC resistance and overall system efficiency.

4. High-Frequency Applications: For applications like induction heating and SiC-based systems, materials with high B-saturation and low core loss are crucial for achieving high efficiency and stability.

 

 

 

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• Introduction to the event and speaker (5 minutes)
• Main presentation by Dr. Sai Ram (50 minutes)
• Q&A session (10 minutes)
• Vote of Thanks

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