Integrated Planar Magnetics Optimization for Δ-Δ LLC Converter with Wide Output Voltage Range

This paper proposes an optimized integrated planar transformer structure and a systematic design framework for a three-phase Delta - Delta connected LLC converter for 48V light electric vehicle charging systems. The proposed integrated magnetics aims to increase the leakage inductance to reduce the switching frequency range for regulating the voltage with a wide range. The proposed methodology uses newly derived first harmonic approximation current equations in relation with the switching frequency, sweeps the L-m/ L-r and Q pairs, and designs integrated magnetics with different asymmetrical winding options, different cores and materials under given constraints. A 1 MHz 3700W / 48V three phases Delta-Delta connected LLC converter has been optimized using the proposed optimization framework. The resultant design employs an integrated magnetic design with two stacked ER32/6/25 cores under the constraint of using a 6-layer board and off-the-shelf ferrite cores, with asymmetric winding turns of 5:1 and 3:1 on the central legs.