Four-Winding Integrated Inductor Transformer Structure for Dual Active Bridge Converter

Abstract

In a dual active bridge converter, the split series inductance configuration with finite magnetizing inductance can provide an additional degree of freedom to optimize the converter's performance. However, this magnetic configuration results in three separate magnetic structures, which increases the volume and footprint. To address this issue, this article proposes a four-winding integrated magnetic structure comprising decoupled primary inductance, secondary inductance, and a transformer capable of independent tuning. The fluxes produced by primary and secondary inductors within the integrated structure consistently oppose in the middle leg of the inductor core, resulting in reduced losses and a smaller volume. A design methodology based on an analytical model has also been developed to systematize the design process. A sensitivity analysis is performed using the finite element method to verify the decoupling operation. An 11 kW, 775 V/450 V prototype is implemented, and the integrated magnetic structure is compared with its discrete implementation under steady-state thermal conditions at different ambient temperatures. A volume reduction of 12.1% and magnetic loss reduction of 4.5% is achieved, while the converter efficiency remains higher or comparable to that of the discrete implementation across the entire operating range.