基于软件集成平台的平面变压器优化设计与仿真的研究
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摘要
采用传统变压器的开关电源在向高功率密度和低造型方向发展时暴露出诸多限制。为了提高功率密度,就得提高变换器的开关频率,从而减小电路中无源元件的体积。但是对于传统线绕式变压器,当开关频率高于100kHz时,变压器圆铜线的高频效应(主要为集肤效应和邻近效应)越来越显著,增加了变压器的损耗。为了削弱高频效应,可采用低造型铁芯以及印刷电路板平面绕组制作而成的平面变压器。与传统线绕式变压器相比,平面变压器具有相当多优点,例如低造型,良好的散热特性,漏感小,可实现特性重现等等,适用于高功率密度高频开关电源。对平面变压器的研究和应用在过去十年得到了快速发展。然而,当开关频率高达数百kHz,甚至大于1MHz时,平面变压器同样受到诸如集肤和邻近效应等高频效应的影响。这些高频效应产生的交流电阻、漏感以及分布电容,增大了开关电源的损耗,其中漏感和分布电容释放储能时产生危及功率开关安全运行的电压尖峰,降低了开关电源的性能,此外由于减小漏感与减小分布电容的要求相矛盾,因此平面变压器的优化设计必须考虑所有寄生效应的影响。
本文提出了一种基于iSIGHT软件集成平台的平面变压器优化设计方法。将电磁分析软件Maxwell 3D和电路仿真软件Saber与优化软件iSIGHT集成,深入研究平面变压器的寄生效应,采取措施降低危及开关安全运行的电压尖峰,改善开关电源的性能,最终获得平面变压器的最优设计。论文的主要成果如下:
1)对平面变压器的特殊结构及绕组绕制方式进行研究,分析各寄生效应产生的原理,以及对电源性能的危害,提出了相应的改进措施,并建立了用于综合分析高频效应和优化设计的平面变压器等效电路。
2)通过对平面变压器高频效应的深入研究,发现电路寄生元件之间会发生谐振,在变换器开关器件两端产生高频高压的尖峰谐波,严重危及开关器件的安全远行,因此确立了尽量减小开关两端电压应力的优化目标,且优化设计变量为变压器原边与副边绕组之间的绝缘层厚度。
3)提出了平面变压器的设计方法;利用电磁仿真软件Maxwell 3D对平面变压器进行了涡流场和静电场分析,根据仿真得到的阻抗矩阵和电容矩阵,推导出了提取平面变压器各寄生参数的方程。
4)在iSIGHT软件集成平台中集成了Maxwell 3D和Saber软件。通过iSIGHT提供的优化算法对平面变压器进行迭代仿真。改变变压器原边与副边绕组之间的耦合程度,根据不同的耦合程度产生不同的寄生效应,对应的寄生元件释放储能产生不同的电压尖峰,从中选出电压尖峰最小所对应的平面变压器设计,从而实
The drive towards higher power densities and overall lower profile in switch mode power supplies (SMPS) has exposed a number of limitations in the use of conventional transformer structures. In order to achieve higher power densities, it has to increase the converter switching frequency to achieve passive component size reduction. However for conventional wire wound transformers this leads to problems of increased loss due to the skin and proximity effects in the round conductors particularly at frequencies above 100 kHz. One possible solution is to employ planar transformer consisted of low-profile core and planar winding fabricated on a printed circuit board (PCB). Unlike conventional wire wound transformer, planar transformer offers many advantages, such as lower profile, good thermal characteristics, small leakage inductance and repeatability, so it is a good solution for high power density high frequency (HF) SMPS. Its research and application are growing in the last decade. However, due to the high switching frequency up to several hundred kHz, even more than 1MHz, planar transformer is also affected by many HF effects like skin and proximity effects. These HF effects produce ac resistances, leakage inductances and distributed capacitances that increase the losses of the SMPS, produce parasitic oscillations with dangerous high voltage spikes, and must be reduced the performance of the SMPS, moreover, reducing leakage inductance has the usually unwanted effects of increasing distributed capacitance, hence an optimal design of planar transformer is necessary to take into account all the parasitic effects.
This paper describes a method of optimizing planar transformers’design based on integrated software platform iSIGHT. Through integrating the circuit simulation tool Saber and Maxwell 3D to the optimization tool iSIGHT, the parasitic effects on planar transformers are studied carefully, and a new method to avoid parasitic oscillations with dangerous high voltage spikes to improve the SMPS performance is established. Hence an optimal design of planar transformer is obtained. The main jobs and conclusions as follows:
Firstly, the special planar structure and winding fabricated means of planar transformer is in-depth studied, including the principle of parasitic effects, their disadvantages to the SMPS performance, and methods to reduce these effects. Hence a high frequency planar transformer model suitable for design, optimization and circuit
本文提出了一种基于iSIGHT软件集成平台的平面变压器优化设计方法。将电磁分析软件Maxwell 3D和电路仿真软件Saber与优化软件iSIGHT集成,深入研究平面变压器的寄生效应,采取措施降低危及开关安全运行的电压尖峰,改善开关电源的性能,最终获得平面变压器的最优设计。论文的主要成果如下:
1)对平面变压器的特殊结构及绕组绕制方式进行研究,分析各寄生效应产生的原理,以及对电源性能的危害,提出了相应的改进措施,并建立了用于综合分析高频效应和优化设计的平面变压器等效电路。
2)通过对平面变压器高频效应的深入研究,发现电路寄生元件之间会发生谐振,在变换器开关器件两端产生高频高压的尖峰谐波,严重危及开关器件的安全远行,因此确立了尽量减小开关两端电压应力的优化目标,且优化设计变量为变压器原边与副边绕组之间的绝缘层厚度。
3)提出了平面变压器的设计方法;利用电磁仿真软件Maxwell 3D对平面变压器进行了涡流场和静电场分析,根据仿真得到的阻抗矩阵和电容矩阵,推导出了提取平面变压器各寄生参数的方程。
4)在iSIGHT软件集成平台中集成了Maxwell 3D和Saber软件。通过iSIGHT提供的优化算法对平面变压器进行迭代仿真。改变变压器原边与副边绕组之间的耦合程度,根据不同的耦合程度产生不同的寄生效应,对应的寄生元件释放储能产生不同的电压尖峰,从中选出电压尖峰最小所对应的平面变压器设计,从而实
The drive towards higher power densities and overall lower profile in switch mode power supplies (SMPS) has exposed a number of limitations in the use of conventional transformer structures. In order to achieve higher power densities, it has to increase the converter switching frequency to achieve passive component size reduction. However for conventional wire wound transformers this leads to problems of increased loss due to the skin and proximity effects in the round conductors particularly at frequencies above 100 kHz. One possible solution is to employ planar transformer consisted of low-profile core and planar winding fabricated on a printed circuit board (PCB). Unlike conventional wire wound transformer, planar transformer offers many advantages, such as lower profile, good thermal characteristics, small leakage inductance and repeatability, so it is a good solution for high power density high frequency (HF) SMPS. Its research and application are growing in the last decade. However, due to the high switching frequency up to several hundred kHz, even more than 1MHz, planar transformer is also affected by many HF effects like skin and proximity effects. These HF effects produce ac resistances, leakage inductances and distributed capacitances that increase the losses of the SMPS, produce parasitic oscillations with dangerous high voltage spikes, and must be reduced the performance of the SMPS, moreover, reducing leakage inductance has the usually unwanted effects of increasing distributed capacitance, hence an optimal design of planar transformer is necessary to take into account all the parasitic effects.
This paper describes a method of optimizing planar transformers’design based on integrated software platform iSIGHT. Through integrating the circuit simulation tool Saber and Maxwell 3D to the optimization tool iSIGHT, the parasitic effects on planar transformers are studied carefully, and a new method to avoid parasitic oscillations with dangerous high voltage spikes to improve the SMPS performance is established. Hence an optimal design of planar transformer is obtained. The main jobs and conclusions as follows:
Firstly, the special planar structure and winding fabricated means of planar transformer is in-depth studied, including the principle of parasitic effects, their disadvantages to the SMPS performance, and methods to reduce these effects. Hence a high frequency planar transformer model suitable for design, optimization and circuit
引文
[1] Rprieto.O.Garcia , R.Asensi , J.A.Cobos . Optimizing the Performance of Planar Transformer.Applied Power Electronics Conference and Exposition.APEC 1996.IEEE 11th Annual Conference.3-7 March 1996.Vol.1:pp415-421
[2] O.Garcia,J.A.Cobos,S.Ollero.A Standard Design Method for High Frequency PCB Transformer . Telecommunications Energy Conference . INTELEC 1995 . IEEE 17th International Conference.29 Oct.-1 Nov.1995.pp335-339
[3] 邢岩,蔡宣三.高频功率开关变换技术.北京:机械工业出版社.2005
[4] 杨玉岗.现代电力电子的磁技术.北京:科学出版社.2003
[5] 李茜.小型高压平面脉冲变压器[硕士学位论文].北京:中国工程物理研究院北京研究生部.2002
[6] Ferroxcube Components Inc.Design of planar power transformer.Application Note,Document Number 9398 083 39011.2001
[7] 张凯,张凯洪,王晓红.平面变压器在高频开关电源中的应用.通信电源技术.2003.4.20(2)
[8] Bruce W. Carsten.The low leakage inductance of planar transformers;fact or myth.Applied Power Electronics Conference and Exposition.APEC 2001.IEEE 16th Annual Conference.4-8 March 2001.Vol.2:pp1184-1188
[9] N. Dai,A. W. Lotfi,C. Skutt,et al.A comparative study of high frequency low profile planar transformer technologies.Applied Power Electronics Conference and Exposition.APEC 1994.IEEE 9th Annual Conference.13-17 Feb. 1994.Vol.1:pp226-232
[10] Zumel. P,Prieto. R,Cobos. J. A,et al.Comparative study of flex-foil technology in HF planar transformer windings.Power Electronics Specialists Conference.PESC 2002.IEEE 33rd Annual Conference.23-27 June 2002.Vol.3:pp1248-1253
[11] N. Dai,F.C. Lee.Edge effect analysis in high frequency transformer.Power Electronics Specialists Conference.PESC 1994.IEEE 25th Annual Conference.20-25 June 1994.Vol.2:pp850-855
[12] X. Huang,K.D.T. Ngo,G. Bloom.Design techniques for planar winding with low resistances.Applied Power Electronics Conference and Exposition.APEC 1995.IEEE 10th Annual Conference.5-9 March 1995.Vol.2:pp533-539
[13] W. Chen,Y.Y. Yan,Y.Q. Hu,et al.Model and design of PCB parallel winding for planar transformer.IEEE Transactions on Magnetics.2003,39(5):pp3202-3204
[14] R. Prieto,J.A. Oliver,J.A. Cobos,et al.1D magnetic component model for planarstructures.Power Electronics Specialists Conference.PESC 1999.IEEE 30th Annual Conference.27 June-1 July 1999.Vol.1:pp574-579
[15] Y.Q. Hu,J.F. Guan,X.M. Bai,et al.Problems of paralleling windings for planar transformers and solutions.Power Electronics Specialists Conference.PESC 2002.IEEE 33rd Annual Conference.23-27 June 2002.Vol.2:pp597-601
[16] 旷建军.平面变压器 PCB 板绕组的损耗分析、计算与设计优化[硕士学位论文].福建福州:福州大学.2001
[17] V. Gregory.Building magnetics with flexible circuits.Power Technics Magazine, 1989 February.5(2):pp16-22
[18] A.J. Yerman,et al.High-frequency transformer.U.S.Patent,No. 4 959 630,September 25th,1990
[19] Y. Q. Hu,D. H. He,T. Y. Jin.Design and application of high-frequency and low-profile power transformers.Power Electronics and Drive Systems.PEDS 1999.Proceedings of the IEEE 1999 International Conference.27-29 July 1999.Vol.1:pp40-45
[20] K.D.T. Ngo,R.S. Lai.Effect of height on power density in spiral-wound power-pot-core transformer.IEEE Transactions on Power Electronics.1992,7(3):pp601-606
[21] 蔡宣三,龚绍文.高频功率电子学.北京:科学出版社.1993
[22] Y.T. Han,W. Eberle,Y.F. Liu.New measurement methods to characterize transformer core loss and copper loss in high frequency switching mode power supplies.Power Electronics Specialists Conference.PESC 2004.IEEE 35th Annual Conference.20-25 June 2004.Vol.2:pp1695-1701
[23] P.L. Dowell.Effects of eddy currents in transformer windings.Proceedings of IEE.1966,113(8):pp1387-1394
[24] G. Skutt,F. Lee,R. Ridley,et al.Leakage inductance and termination effects in a high power planar magnetic structure.Applied Power Electronics Conference and Exposition.APEC 1994.Proceedings of the IEEE 9th Annual Conference.13-17 Feb. 1994.Vol.1:pp295-301
[25] 赵修科.实用电源技术手册,磁性元器件分册.辽宁沈阳:辽宁科学技术出版社.2002
[26] 周邦雄.实用电源技术手册.吉林长春:吉林电子出版社.2004
[27] 王全保.电子变压器手册.辽宁沈阳:辽宁科学技术出版社.2000
[28] 吴建强,吴辉,郭兴宽.吸收法抑制高频高压变压器分布电容的研究.电力电子技术.2002.12.36(6)
[29] 曾光,金舜,史明.高频高压变压器分布电容的分析与处理.电力电子技术.2002.12.36(6)
[30] 薛蕙,劲力.PCB 平面型高频电源变压器研究.国际电子变压器.2005.4.5(4)
[31] Mulder S.A . Application note on the design of low profile high frequencytransformers.Ferroxcube Components Inc.1990
[32] 张占松,蔡宣三.开关电源的原理与设计.北京:电子工业出版社.2002
[33] 刘国强,赵凌志,蒋继娅.Ansoft 工程电磁场有限元分析.北京:电子工业出版社.2005
[34] 刘红.有限元基本概念和原理.计算机世界日报.2001.4.14
[35] Ansoft Co. Ltd.Maxwell 3D 产品功能详情.www.ansoft.com.cn.2002
[36] iSIGHT——多学科设计优化集成平台.CAD/CAM 与制造业信息化.2003.12.10(12)
[37] 耿建光.工程系统过程集成和设计优化——iSIGHT 中的过程集成与设计自动化.军民两用技术与产品.2002.11.15(11)
[38] 赛特达科技有限公司.iSIGHT 简介——提示产品性能和质量的多学科综合设计优化平台.www.sightnacorp.com
[2] O.Garcia,J.A.Cobos,S.Ollero.A Standard Design Method for High Frequency PCB Transformer . Telecommunications Energy Conference . INTELEC 1995 . IEEE 17th International Conference.29 Oct.-1 Nov.1995.pp335-339
[3] 邢岩,蔡宣三.高频功率开关变换技术.北京:机械工业出版社.2005
[4] 杨玉岗.现代电力电子的磁技术.北京:科学出版社.2003
[5] 李茜.小型高压平面脉冲变压器[硕士学位论文].北京:中国工程物理研究院北京研究生部.2002
[6] Ferroxcube Components Inc.Design of planar power transformer.Application Note,Document Number 9398 083 39011.2001
[7] 张凯,张凯洪,王晓红.平面变压器在高频开关电源中的应用.通信电源技术.2003.4.20(2)
[8] Bruce W. Carsten.The low leakage inductance of planar transformers;fact or myth.Applied Power Electronics Conference and Exposition.APEC 2001.IEEE 16th Annual Conference.4-8 March 2001.Vol.2:pp1184-1188
[9] N. Dai,A. W. Lotfi,C. Skutt,et al.A comparative study of high frequency low profile planar transformer technologies.Applied Power Electronics Conference and Exposition.APEC 1994.IEEE 9th Annual Conference.13-17 Feb. 1994.Vol.1:pp226-232
[10] Zumel. P,Prieto. R,Cobos. J. A,et al.Comparative study of flex-foil technology in HF planar transformer windings.Power Electronics Specialists Conference.PESC 2002.IEEE 33rd Annual Conference.23-27 June 2002.Vol.3:pp1248-1253
[11] N. Dai,F.C. Lee.Edge effect analysis in high frequency transformer.Power Electronics Specialists Conference.PESC 1994.IEEE 25th Annual Conference.20-25 June 1994.Vol.2:pp850-855
[12] X. Huang,K.D.T. Ngo,G. Bloom.Design techniques for planar winding with low resistances.Applied Power Electronics Conference and Exposition.APEC 1995.IEEE 10th Annual Conference.5-9 March 1995.Vol.2:pp533-539
[13] W. Chen,Y.Y. Yan,Y.Q. Hu,et al.Model and design of PCB parallel winding for planar transformer.IEEE Transactions on Magnetics.2003,39(5):pp3202-3204
[14] R. Prieto,J.A. Oliver,J.A. Cobos,et al.1D magnetic component model for planarstructures.Power Electronics Specialists Conference.PESC 1999.IEEE 30th Annual Conference.27 June-1 July 1999.Vol.1:pp574-579
[15] Y.Q. Hu,J.F. Guan,X.M. Bai,et al.Problems of paralleling windings for planar transformers and solutions.Power Electronics Specialists Conference.PESC 2002.IEEE 33rd Annual Conference.23-27 June 2002.Vol.2:pp597-601
[16] 旷建军.平面变压器 PCB 板绕组的损耗分析、计算与设计优化[硕士学位论文].福建福州:福州大学.2001
[17] V. Gregory.Building magnetics with flexible circuits.Power Technics Magazine, 1989 February.5(2):pp16-22
[18] A.J. Yerman,et al.High-frequency transformer.U.S.Patent,No. 4 959 630,September 25th,1990
[19] Y. Q. Hu,D. H. He,T. Y. Jin.Design and application of high-frequency and low-profile power transformers.Power Electronics and Drive Systems.PEDS 1999.Proceedings of the IEEE 1999 International Conference.27-29 July 1999.Vol.1:pp40-45
[20] K.D.T. Ngo,R.S. Lai.Effect of height on power density in spiral-wound power-pot-core transformer.IEEE Transactions on Power Electronics.1992,7(3):pp601-606
[21] 蔡宣三,龚绍文.高频功率电子学.北京:科学出版社.1993
[22] Y.T. Han,W. Eberle,Y.F. Liu.New measurement methods to characterize transformer core loss and copper loss in high frequency switching mode power supplies.Power Electronics Specialists Conference.PESC 2004.IEEE 35th Annual Conference.20-25 June 2004.Vol.2:pp1695-1701
[23] P.L. Dowell.Effects of eddy currents in transformer windings.Proceedings of IEE.1966,113(8):pp1387-1394
[24] G. Skutt,F. Lee,R. Ridley,et al.Leakage inductance and termination effects in a high power planar magnetic structure.Applied Power Electronics Conference and Exposition.APEC 1994.Proceedings of the IEEE 9th Annual Conference.13-17 Feb. 1994.Vol.1:pp295-301
[25] 赵修科.实用电源技术手册,磁性元器件分册.辽宁沈阳:辽宁科学技术出版社.2002
[26] 周邦雄.实用电源技术手册.吉林长春:吉林电子出版社.2004
[27] 王全保.电子变压器手册.辽宁沈阳:辽宁科学技术出版社.2000
[28] 吴建强,吴辉,郭兴宽.吸收法抑制高频高压变压器分布电容的研究.电力电子技术.2002.12.36(6)
[29] 曾光,金舜,史明.高频高压变压器分布电容的分析与处理.电力电子技术.2002.12.36(6)
[30] 薛蕙,劲力.PCB 平面型高频电源变压器研究.国际电子变压器.2005.4.5(4)
[31] Mulder S.A . Application note on the design of low profile high frequencytransformers.Ferroxcube Components Inc.1990
[32] 张占松,蔡宣三.开关电源的原理与设计.北京:电子工业出版社.2002
[33] 刘国强,赵凌志,蒋继娅.Ansoft 工程电磁场有限元分析.北京:电子工业出版社.2005
[34] 刘红.有限元基本概念和原理.计算机世界日报.2001.4.14
[35] Ansoft Co. Ltd.Maxwell 3D 产品功能详情.www.ansoft.com.cn.2002
[36] iSIGHT——多学科设计优化集成平台.CAD/CAM 与制造业信息化.2003.12.10(12)
[37] 耿建光.工程系统过程集成和设计优化——iSIGHT 中的过程集成与设计自动化.军民两用技术与产品.2002.11.15(11)
[38] 赛特达科技有限公司.iSIGHT 简介——提示产品性能和质量的多学科综合设计优化平台.www.sightnacorp.com