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Cd.aai.Msthor

A Novel Iron Loss Calculation Method on Power Converters

Based on Dynamic Minor Loop

Seiji Jyasu, Toshihisa Shimizu Kenichiro Ishii

Department of Electrical Engineering Toho Zinc Co., Ltd.
Tokyo Metropolitan University Naka 387, Fujiokashi
1, Minami-osawa 1 Gumua 375-0005, JAPAN
Hachioji 192-0397, JAPAN
Tel.: +81-426-77-1111
Fax: +81-426-77-2737
E-Mail: shimizu @eei.metro-u.ac.jp

Keywords
((Magnetic device)), ((Mcasuremcnt)>, ((Passivc component))

Abstract
The authors have reported a novel iron loss calculation method based on a loss-map of the mag-
netic materials. A distinctive feature of this method is that the iron loss on the inductors can easily be
calculated in many kinds of converters dynamically. The dynamic measuring method of the dynamic
minor-magnetic loop by using the buck-chopper circuit is presented. Next. some typical characteristics
of the loss map derived from the dynamic minor loop measurement is discussed. Also, a novel iron
loss calculation method of the ac filter inductor on the PWM inverter by using the loss-map method is
described. Some experimental results shows that the iron loss obtained from this calculation method
coincides well with the actual one.

1 Introduction
In recent years, remarkable loss reduction of the power semiconductors have been achioved, and as
a result, the loss of the magnetic components. such as the transformers and the inductors, used in the
power converters becomes relatively increasing. In order to increase both the conversion efficiency and
the power donsity of the powor converters, a study on the loss ieduction method on the magnetic compo-
nent is one of the most important issue among the power electronics authorities. Traditionally, reduction
methods of the magnetizing loss on the transformers and the ac motors have been studied[l]-[4]. How-
ever, only a few papers have been reported the inductor iron loss on the ac/dc filter inductor under the use
of the high-frequency PWM switching condition. The iron loss on the transformers and the inductors de-
pends deeply on both the amplitude and the waveform of the magnetizing current flowing thorough them.
Especially on the inductors, the low-frequency current depends on the output current, and the amplitude
of the high-frequency tipple current depends on the modulation condition of the converters[7]. This
means that the magnetic operating point and the shape of dynamic minor loop are changed according to

HIEL 2005 - lsc ISBN 90-I71S08-1 R

A Novel iron Loss Calclaaioi Method on PDowr Convers BaWd on iJynanir MinorLool) SSlhLrvlLU Toslihis&a

(a) Q O-N IOFF I

V IdT *(I -d)7L-

(b)

t' 0

tI
Vi 2K~D C R X§~ (d) H
Al NH~ Ho

B(e) JB Bo

(a) BuLck chopper circuit () Operation wavoforms oni tlhe

chopper circuit.
Fig. 1: The buck chopper circuit and its operation wavefonns.

the instantaneous amplitude of the low-frequency current. Also, the sum of the loss caused by dynamic
minor loop usually dominate the iron loss of the inductor. Hence the loss calculation on the inductors
are usuallycomplicated compared to that on the transformers. However the iron loss causod by the high-
frequency ripple current on above condition is difficult to calculate because the magnetic component
suppliers provide only a few loss data taking those high frequency ripple current into account. P.Tenant
et.al have roported a prediction mothod of the iron loss of the inductor used on the DC-DC converters
based on the prediction of the dynamic minor loop [5]. In this method, the iron loss is calculated based
on the numerical minor-magnetic loop which takes hysteresis loss, eddy current loss, and residual loss
into account. However, some experimental data is necessary in order to adlust the numerical parameter
in the numerical equation. Then. it is difficult to apply this method in designing the inductor used in
many kinds of converters on the different conditions.
The authors have reported a novel iron loss calculation method based on the loss-map of the magnetic
materials[&]. A distinctive feature of this method is that the iron loss on the inductor can easily be
calculatod in many kinds of converters. Then, the dynamic measuring method of the dynamic minor-
magnetic loop by using the buck-chopper circuit is presented. Next, somne typical characteristics of the
loss mnap derived from the dynamic minor-magnetic loop mieasuremient is discussed. Also, a novel iron
loss calculation method of the ac filtor inductor on the PWM inverter by using the loss-map method is
described. Some experimental results shows that the iron loss obtained from this calculation method
coincides well with the actual one. Finally, conclusion and our future worls are mentioned.

2 Dynamic Minor Loop on the Inductor

Firstly, we briefly review the dynamic minor loop and the resultant iron loss under the condition
of rectangular voltage excitation. Figs.1(a) and (b) show the buck chopper circuit and its operation
wavefoms. The waveforms of both the magnetic field, H, and the flux density, B, strongly depond on
the induced voltage, the frequency and the current. which contains the ripple component and the dc-bias
component. The amplitude of the magnetic field ripple, AH, the amplitude of the flux donsity ripple, AR,

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DEl 2005 -- L)i--;c11i
12'rr4en ISBN :90-75815-08-5
90-75815-08-5 P.2
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AN L Ls Cd.aai.Msthor SHd.U
Taa sah.

HIEL 2005 - lsc ISBN 90-751S08-5 1'.3

A Nl Ls Cd.ai Nd
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½''t

Fig. 3: Mesuring system.

Table I: Specification of Inductor (SK-14M).
Core Matelial iron Powder
Shape Toroidal
Effctivc Magnetic Path Length Ir 61.24 un
Elfective Cross Sectonal Area Se 74.19 r 2
Volum Ve 4543 r 3
Weight M 32g
Ttan N 50 turn
Inductance L 266 pH

3 Measuring System
Fig.3 shows the measuring system for the dynamic minor loop of the inductor under the rectangular
voltage excitation. In order to induce the rectangular voltage to the inductors, the buck chopper circuit
is used. The synchronization between the BH analyzer and the chopper operation, and phase angle
corTection of the detected signal of B and H, arc the key technology for the accurate measuring[8].
Table.I shows the specification of the inductor used under the test. In order to avoid the influence of air
gap, a toroidal core was used.

4 Measured Results and Loss Map on the Inductor

4.1 Influence of Bias Magnetic Field
In Fig.3, the duty ratio of the switch, Q, is set to 50%. By changing the output current, I., from t.5 A
to 8 A. the bias magnetic field. H0, is changed from 1230 A/m to 6500 A/rn. The iron losses are measured
under two conditions, such that AB is kept constant or AH is kept constant regardless of change of H,.
The "constant AB" condition corresponds to the operation under the pulse width modulation, and the
"constant AH" condition corresponds to the operation under the current hysteresis modulation. Fig.4
shows the experimental results of the dynamic minor loop under above conditions as the bias magnetic
field, H0, is changed from 1230 A/m to 6500 A/in. Figs.4(a) and (b) show that the value of AH and the
area surrounded by the dynamiic minor loop increases as the bias magnetic field Ho. increases under
the "constant AB" condition. This is because that the inductance ,L, reduces as the bias magnetic field,
Ho increases. This fact shows the iron loss increases as the bias magnetic field. Hot increases under

kl'L 2005 - lsc ISBN 90-I71S08-O P'.

A -Novcl ion Los CO lCulittiaon Melil o-n Power Convmrtei IAscxd on [yn nic Minor Loop SHlLAlZU ToslLilii,--

200OAfni 2000A/rm 200OA/rm

CB7 B

StL O O m T L$tL LsIyI OOMT 7tOOMT 100

ir

IOW A/rn/di% ICM A/ -i-H: 1000 A/u/div

L
5~~~~~0eTdvL B: OUs0 T/divK IB __
:
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(a) AB 400 mT, AH = 26 A/rm, (b) The conistant AB" condition (AB = Cc) The "conistatir AH" condition (AH =

11 - I230A/in, 400 rnT,11, 6500Aim), 2600OA/nmIn - 6500A(m)m -

Fig. 4: Dynanic miagnetic minor magnetic loops when AH kept constant and AB kept constant.

the "'constant AR" cond(iition. Figs.4(a) and (c) shoow that the value of AB and the area surrounded by
the tynamic
i mior toop decreases even though bias magnietic field, H0, increases under the "constant
AlT" condiLion. This is because that Lhe shape of the loop comes to narow bias magnetic fLeld, H, as

increases under the "constant All" condition.

It should be noted that the switching frequencv increases as the the bias magnetic field. H, incoreases
under the "constant All condition, because the inductance of the inductor decreases at high output
current conlition. From above results, we can expect that the iron loss decreases as the bias magnetic
field, H0, increases under the "constant All" condition. even if the switching frequency is increased.

However these characteristics, of course. may depend strongly on te kInd of the magnetic materiaLs.

4.2 A Novel Loss Map of Magnetic Material

Fig.5 shows the novel loss mnap obtained froom above m-entioned experimental resulIs. The loss map
is expressed by bias magnetLe field, H0, and area of dynamic minor loop [J/m3] with parameters of AH
and AR. This loss map does not depenid on the core size and turn ntunber of the windingi since BH-cruve

characteristics depend oni onily the core miw-aterial. Then this loss map enables to predict the ironi loss of the
inductors umder arbitrary conditions. In the case when we calculate the iron loss of Lhe filLer indLucLor on
DC-DC converters, the iron loss can be calculated very easily. Substittuting some operation parameters
oti the iniducto-r in the equation (1) and (3), then we read out the value of the minor loop's area oni the loss
map. Finally we can get the ironi loss by multiplying the area of this loss map by switching frequency
and the volume of the coro. At very high frequency condlitions, oddy current loss and residual loss can
not be negligible and the actal area surrounded by the dynamic minor loop will increase from the area
shown in -this loss map. this case, it is enough to iiiultiply the value of the area oln the loss map by

some coefficient.

P.S
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IPE 2005
2,005 -- Drerden
Dm-4-n ISB'i: w4$7515-08-5 P.5
ISBN:
AN lls Cd.aai.MNlc6 o5 iias oa SiU Ts sit
Mcro

180 _ 400 my conlsort rT

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100
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60
40 AB consLant
20 --_ ~_ a-__

I -w~
- AHM constanit
0
I _
-_-__
+ X }-______

0 2000 4000 6000 8000

Bias magnetic field H, [A/m]

Fig. 5: Proposed Loss Map.

E/2_1
-H
=r
I T

Fig. 6: Single phase PWM inverter.

5 A Novel Calculation Method of AC Filter Inductors on Voltage

Source PWM Inverters
5.1 Dynamic Minor Loops of AC Inductors on PWM Inverters
Fig.6 shows a single phase PWM inverter including an AC filter circuit. Fig.7(a) shows the operation
waveforms and Fig.7(b) shows a part of the dyanamic minor loop of the AC inductor core which cor-
respond to the portion surrounded by the circles in Fig.7(a). As shown in Fig.7(a), bias magnetic field
changes dynamically due to the change of output current. Then, the dynamic loop of the AC inductor
core in one switching period becomes to open-loop shape. as shown in Fig.7(b). It seems to be difficult
to predict the iron loss because the trajectory does not form closed-loops at each switching interval.

5.2 Approximation Method of the Dynamic Minor Loops

In order to make the iron loss calculation possible, this paper presents an approximation method of
the dynanic minor loop of AC filter inductor. The open-looped dynanic minor loop in one switching
period on the PWM inverter is approximated to the quasi-closed loop as shown in Fig.8. The open-loop
is transformed into quasi-closed loop so that the line PQ is superimposes on the line QR. This quasi-
closed loop area gives an approximated area for the iron loss during one switching period. The dynanic

HIEL 2005 - 1dc ISBN 90-75S=08-5 1'.6

AN L Ls Cd.aai.Msthor SHd.U
Taa sah.

HIEL 2005 - lsc ISBN 90-751S08-3

A Novel Iron Loss Calcladon Method on Pow-er Converters Based on Dynamnic Minor Loop SHlKIElJZ Toshihisa

B B
Q Q

IP
R
I
Pv
R
rsI

H Ho
H H
(a) Dynamic minor loop on PWM (b) Quasi-closed loop.
inverter at one switching period.
Fig. 8: Approximation to the quasi-closed loop.
Table IL: Circuit parameters.
InpuLt Voltage E 60V
Output Filter Inductance L (Table. 1) 266pH
Output Filter Capacitance C 50pF
Output Resistance R 10 t.
Output Frequency f, 50 Hz
Switching Frequencyf, 15 kHz
Modulation Index 0.8

500A/m [T 500 A/m

0.2

3.15

J$5O~5mT
5.1

L 1006 1500 2000 2500 3000

FA /m,l
(a) Under Ho constant exci- (b) Under the PWM inverter.'
tation ,which is the rectungur
voltage excitation on the buck
chopper circuit.
Fig. 9: Dynamic minor loops when AB=235 mT, H0=2000 A/m.

5.4 Verification of Inductor Iron Loss Calculation Method on PWM Inverters

The proposed iron loss calculation can be executed by P-SIM. Table.II shows the circuit parameters on
the simulation. Fig. 12(a) shows the simlated result of the inductor current, iL, the inductor voltage, 0L,
the bias magnetic field, H0, the flux density ripple, AB, and Fig. 12(b) shows the change of minor loop's
area on the loss map. Table.III shows the the iron loss obtained from both the calculation method and
the experimental setup. In order to measure the iron loss, the power-analyzer PZ4000(YOKOGAWA)
was used. Taking the error of the power analyzer and the error of the loss map into account, it can be
concluded that the calculated loss coincide well with the measured one. Hence, it is verified that the

EPE 2005 -- Dresden

EPIE 200-5 1SBN: 90-75815-08-5
P.O
P.8
A Novel iron Loss Calalationi Mthod oni PDor Convcrs Ba8c on Iynanic MinorLool) SSlhLrvlLU Toslihis&a

8
6
4
2°

300

E 2004
01 00
o

E | PWM|
4] -> Loss mapl lll
Ln~~~~~~~~~~~n 2 ins

Fig. 10: Experimental results and the areas obtained from the loss map.
Ho - < Loss map

IL ~~

dI 1
f uLdt 6;S N
C);
JVS
8
I

G0

Bias magletic field H0 [A/m]

Fig. 11: Iron loss calculation method on PWM inverters,

proposed iron loss calculation method of the ac filter inductor on the PWM inverter is useful.

6 Conclusions
The iron loss of the filter inductor on the power converters is discussed. A novel loss map of magnetic
material on the basis of the dynamic minor loop is doscribed. This loss map enables to predict tho iron
loss of the inductor on DC-DC converters very easily. A calculation method of the iron loss of the ac
filter inductor on PWM invertcr is also proposed. It is verified that the calculated results of the iron loss
of the AC filter inductor on the PWM inverter coincide well the those on the experimental set up. It is
concluded that the proposed loss map and the iron loss calculation method is useful for designing the
optimal inductor used on tho switching converters. Based on the proposod loss map, development of the
optimal modulation method that mitigates the inductor loss on the inverter is the future work.

12K
P.9
DEl 2005 -- L)i--;c11i
I2'rc.xkn ISBN :90-75815-08-5 1'.9
ISBN
AN L Ls Cd.aai.Msthor SHd.U
Taa sah.

HIEL 2005 - lsc ISBN 90-751S08-l 1'.10