10th International Conference on Power Electronics-ECCE Asia

May 27 - 30, 2019 / BEXCO, Busan, Korea

Design of Optimized Coupling Factor for Minimum Inductor

Current Ripple in DC-DC Converter using Multi-winding
Coupled Inductor
Taewon Kang1, Jaeho Lee, and1 Yongsug Suh2
1
R&D Center, CORE Electric Co. LTd., Korea
2
Dept. of Electrical Engineering, Smart Grid Research Center, Chonbuk National University, Korea

Abstract— The magnetic coupling of filter inductors is In the passenger car industry, the electric vehicle has
widely utilized in various power electronics application fields, recently become widely accepted by the general public.
including dc-dc converters in EV charger systems, in order The improvement of battery and charging technique is an
to enhance the filtering performance while maintaining the important contribution to this wide acceptance [1–4]. In
minimal filter size. The optimal distribution of self and
general, power electronics plays a significant role in
mutual inductance of the coupled inductor is regarded as one
of the important design tasks with respect to the coupled
battery charging technique, including EV and PHEV
inductor. This paper proposes a novel method to design the charging systems. In power electronic solutions of
optimal coupling factor for a generalized n-winding coupled chargers, parallel connected multiple bidirectional dc-dc
inductor, which generates the least size of inductor current converters with active or diode bridge front-end rectifier
ripple in phase-staggered multi-paralleled dc-dc converters. are well adopted in the industry. Phase-staggering
The explicit mathematical form of the optimal coupling operation of multiple bidirectional dc-dc converters is
factor for a generalized n-winding coupled inductor in n- considered to reduce the ripple size of summed inductor
phase staggered multi-paralleled dc-dc converters is currents and filtering requirement for battery charging
presented. The general equations for the n-winding coupled
current. Reduction of the inductor current ripple by a
inductor are verified through the example case of the 3-
winding coupled inductor. The experimental results
coupled inductor in the interleaving structure has also been
successfully confirmed the newly proposed method of proposed. A coupled inductor can decrease the physical
obtaining the optimal coupling factor. size of the inductor itself, while still complying with the
Index Terms—Coupled inductor, Interleaved dc-dc peak switching current requirements from power
converter, Coupling factor (Coupling coefficient), Phase- semiconductor switches in dc-dc converters [5–7]. Table I
staggering, Magnetic coupling. summarizes the design and analysis of two or multi-
winding coupled inductors that have been reported in
previous literature.
I. INTRODUCTION The coupling factor of the coupled inductor has a
NOMENCLATURE significant impact on the phase-staggering operation of
𝑉1 , 𝑉2 … 𝑉𝑛 Inductor voltage multiple bidirectional dc-dc converters. The selection of
the optimal magnetic structure and coupling factor is
𝑉𝑇 Sum of inductor voltage regarded as an important task in designing a coupled
𝑖1 , 𝑖2 … 𝑖𝑛 Inductor current inductor. However, little work in previous literature has
𝑛 Number of winding
focused on the optimal coupling factor of a coupled
inductor, and its relationship with the operation of dc-dc
Self inductance in symmetrical core
𝐿𝑛𝑛 converters. Also, previous research into the hardware
structure
Self inductance in symmetrical core design of the coupled inductor has paid less attention to the
𝐿𝑠 design elements, such as the core material, core structure,
structure ( 𝐿𝑛𝑛 = 𝐿𝑠 )
Mutual inductance in symmetrical core and air gap, for the coupling factor. In addition, the
𝐿(𝑛−1)𝑛
structure investigation of the generalized n-winding coupled
Mutual inductance in symmetrical core inductor with respect to the selection of coupling factor has
𝐿𝑚
structure ( 𝐿(𝑛−1)𝑛 = 𝐿𝑚 ) not been fully covered [8, 9].
𝐿𝑒𝑞 Equivalent inductance This paper investigates the design of the coupled
Coupling factor ( 𝑘 =
𝐿𝑚
)
inductor for minimum inductor current ripple in rapid
k 𝐿𝑠 battery charger systems. Figure 1 shows the topology of
∆𝑖𝐿 Ripple of inductor current the non-isolated dc-dc converters connected to a common
D Duty ratio dc link, which is a target rapid charger in this paper. This
topology can become a potential solution in a micro grid
𝑉𝑖𝑛 Input voltage system, or in clustered charging stations with a common
1
𝑓𝑠 Switching frequency ( 𝑓𝑠 = ) front-end rectifier. As compared to previous literature, this
𝑇𝑠
m Interval value
paper newly proposes a generalized approach to model the
n-winding coupled inductor and obtain the optimized
coupling factor for the minimal inductor peak current.

ⓒ2019 KIPE 242

 TABLE I. SUMMARY OF PREVIOUS RESERCH WORK ON THE COUPLED INDUCTOR.

In this paper [8] [9] [10] [11] [12] [13] [14]

Bi-directional dc-dc Bi-directional dc- Boost 3-level dc-dc Bi-directional dc-

Topology PFC converter Buck converter Boost converter
converter dc converter converter converter dc converter

Number of
n n 2 2 2 and 3 n 2 2
winding

Analysis Inductor voltage Inductor voltage Kirchhoff’s law and IWCI Pole voltage Magnetic circuit Inductor voltage Magnetic circuit
method equation equation Faraday’s law method equation equation equation equation

Inductor current Transient response, Flux for core Inductor Inductor current Analysis of
Design target Maximum flux Core design
ripple Current ripple size current ripple ripple CCM, DCM

Coupling Optimal k under -0.622 under 2-

Negative Negative Negative Negative Negative Negative
factor (k) each duty cycle winding

The influence of the coupling factor of the coupled

inductor on the operation of interleaved dc-dc converters II. MODELING OF THE COUPLED INDUCTOR
is studied. The selection of the optimal coupling factor Figure 1 shows a schematic of the rapid charger system
under various operating conditions is also presented. The considered in this paper. The overall battery charging and
selection is based on the explicit formula of the optimal discharging system consists of an active front-end rectifier
coupling factor versus the duty ratio of the dc-dc converter of neutral point clamped 3-level type and a non-isolated
generating the least ripple size of the inductor current. bidirectional dc-dc converter of multi-phase interleaved
This paper is structured in three main sections, as half-bridge topology. Figure 2 shows that power can flow
follows. Section II describes the modeling of the n- in both directions within a Battery Charging Unit (BCU).
winding coupled inductor considered in this paper. Section The large ripple in battery charging current incurs stresses
III explains the analysis and design process for the optimal in the battery, and eventually shortens the lifetime of the
coupling factor of the coupled inductor having n-windings battery. In order to reduce the ripple of the battery charging
in n-phase parallel-connected dc-dc converters. Section IV current and the size of the filter inductor, coupling of
shows include the proposed design rule of coupled output inductors in multi-phase interleaved dc-dc
inductor in rapid electric vehicle charging system. Section converters is employed. Figure 3 shows the general form
V presents simulations, as well as experimental results. of the interleaved bi-directional dc-dc converter with the
The design methodology and explicit equation of the n-winding coupled inductor core structure.
optimal coupling factor of coupled inductor make it This paper presents the analysis and design of the
possible to achieve the lower ripple size of inductor current, coupling factor value of the n-winding coupled inductor.
while keeping low material cost for the filter inductor, Also in this paper, the proposed generalized approach for
leading to a greater switch’s device margin, and larger the n-winding coupled inductor is verified through the
power density of magnetic components [10]. example case of the 3-winding coupled inductor. Figure 4
IDC_link_output
IDC_output

IDC_link_ripple FWDARUC1 FWDARUB1 FWDARUA1

SWARUC1 SWARUB1 SWARUA1

VDC_link/2 CDC_link FWDARUC2 FWDARUB2 FWDARUA2

Multi Phase
NPD_C1 NPD_B1 NPD_A1
SWARUC2 SWARUB2 SWARUA2 IAC_input
LAC_input
va
VDC_output

EV
Battery Battery vLL
vb
Charging
vc
Unit Input Filter
FWDARUC3 FWDARUB3 FWDARUA3

NPD_C2 NPD_B2 NPD_A2 Unit

VDC_link/2 CDC_link SWARUC3 SWARUB3
SWARUA3

FWDARUC4 FWDARUB4 FWDARUA4

SWARUC4 SWARUB4 SWARUA4

DC Link Unit Active Rectifier Unit

Figure 1. The proposed battery charging and discharging inverter system.

243
shows the typical structure of the 3-winding coupled
inductor employed for the verification test. The figure
shows that the core structure is made of laminated iron
core and has the benefit of easy control of the coupling
factor during the manufacturing process. Also, compared
to the one in Fig. 3, the core structure in Fig. 4 is superior
with respect to manufacturing cost. Figures 5 shows
photos of the proto-type 3-winding coupled inductor used Figure 6. Circuit modelling of the n-winding coupled inductor.
in the hardware verification test. Among many design factors related to the coupled
inductor, the coupling factor between multiple windings
SW1
+
plays an important role in determining various

Module 1
L1 i1

+ SW1 characteristics of the coupled inductor, such as the ripple

size of inductor current. It is of high practical importance
SW2 to find an optimized coupling factor that generates the least
i2 Module 2
L2 ripple size of the inductor current under different operating
Vinput
Cinput

SW2
conditions. The optimized coupling factor for the
Coutpu
Voutput

.
t

. .
. .
minimum inductor current ripple is derived based on the
.
equivalent circuit of the coupled inductor in Fig. 6, and the
SWn
phase-staggering operation of the multi paralleled buck
Module n

in
Ln
converters in Fig. 2. In general, the inductor voltages of the
-
SWn
- coupled inductor can be represented by the self and mutual
inductances as in (1) and (2):
Figure 2. The bi-directional DC-DC converter used in the Battery
𝑑 𝑑 𝑑 𝑑
Charging Unit (BCU). 𝑉1 = 𝐿11 𝑖 + 𝐿12 𝑖2 + 𝐿13 𝑖3 +. . . +𝐿1𝑛 𝑖𝑛 ,
𝑑𝑡 1 𝑑𝑡 𝑑𝑡 𝑑𝑡 (1)

The coupled inductor has a symmetric magnetic 𝑑 𝑑 𝑑 𝑑

structure. Figure 6 shows the equivalent circuit of the
coupled inductor. The equivalent circuit of the coupled
inductor is based on the transformer equivalent circuit. The
circuit basically consists of n leakage inductances and one
mutual inductance. The core structure has n legs of radial
type core, so that the coupling factor between n-windings
can be adjusted by the air gap distance in the center leg.
The number of core legs is proportional to the number of
phase for the interleaved operation.
Figure 3. Magnetic structure of the Figure 4. Core structure of
coupled inductor employed the 3-winding coupled
in the dc-dc converter. inductor.
Figure 5. Photo of the 3-winding coupled inductor for test set-up
𝑉𝑛 = 𝐿𝑛𝑛 𝑖 + 𝐿𝑛1 𝑖1 + 𝐿𝑛2 𝑖2 +. . . +𝐿𝑛(𝑛−1) 𝑖𝑛−1 ,
𝑑𝑡 𝑛 𝑑𝑡 𝑑𝑡 𝑑𝑡 (2)
𝐿𝑚 𝐿𝑚 𝐿𝑚
𝑘= = =⋯= .
√𝐿11 𝐿22 √𝐿11 𝐿33 √𝐿11 𝐿𝑛𝑛 (3)
In equations (1) and (2), 𝐿11 , 𝐿22 , and 𝐿𝑛𝑛 represent
the self-inductance terms, while 𝐿12 , 𝐿1𝑛 , 𝐿2𝑛 , and
𝐿(𝑛−1)𝑛 represent the mutual inductance terms of the n-
winding coupled inductor. The n subscript represents the
corresponding winding of the coupled inductor. In this
paper, all self-inductance terms are assumed to be equal,
and are defined as 𝐿𝑠 . In addition, all mutual inductances
are also assumed to be equal, and are defined as 𝐿𝑚 . This
assumption is quite realistic in a symmetrical core
structure, as described in Figs. 3 and 4. The mutual
inductance (𝐿𝑚 ) term can be either positive or negative,
depending on the direction of mutual flux coupling. The
positive mutual inductance is referred to as the direct
coupling, while the negative is for the inverse coupling.
The coupling factor (k) is the key design factor in a
coupled inductor, and is defined as in (3). Note from Fig.
3 that under the condition of complete coupling of n-
windings, the mutually coupled flux linkage becomes 1 /
(n - 1) of self-flux linkage, due to the n-legged symmetrical
core structure. Therefore, the coupling factor k takes a
value between (–1 / (n-1) and 1 / (n-1)). In the generalized
model of the n-phase coupled inductor, there are three
possible cases with respect to the sign combination of the
coupling factors among all winding pairs, as the following:
[Case 1] All inverse coupling; negative coupling factors.
[Case 2] All direct coupling; positive coupling factors.
[Case 3] Mixture of inverse and direct coupling between
different pair of windings.

244
 It is readily understood that Case 3 would generate a switching state and the value of p(t) is shown in Fig. 7.
different ripple size of inductor current for each phase. Using of p(t), the sum of voltage (𝑉𝑇 ) can be expressed as,
This non-uniform distribution of current among each
winding in the n-phase coupled inductor is not considered 𝐷
𝑉T = 𝑝(𝑡)𝑉1 + (𝑛 − 𝑝(𝑡)) (− )𝑉 . (9)
to be a practical solution. Case 2 is regarded as a physically 1−𝐷 1
impossible magnetic condition, because all the mutual The values of winding voltages in (7) and (9) can be
fluxes cannot be direct, i.e. additive, at the same time for simplified into (10). Equation (11) is an extended
all winding pairs. This is basically due to the reciprocal representation of (10) for the 3-winding coupled inductor.
characteristic of magnetic coupling between two windings.
Therefore, throughout this paper, Case 1 is only considered,
and negative coupling factor is employed in the analysis.

𝑑 𝑑 𝑑
𝑖1 0 𝑖 … 𝑖
𝑉1 𝑑𝑡 𝑑𝑡 2 𝑑𝑡 𝑛
𝑑 𝑑 𝑑
𝑉
[ 2 ] = 𝐿𝑠 𝑑𝑡 𝑖2 + 𝐿𝑚 𝑑𝑡 𝑖1 0 … 𝑖
𝑑𝑡 𝑛 , (4)
⋮
𝑉𝑛 ⋮ ⋮ ⋮ ⋱ ⋮
𝑑 𝑑 𝑑
[𝑑𝑡 𝑖𝑛 ] [𝑑𝑡 𝑖1 𝑖
𝑑𝑡 2
… 0 ]

𝑉𝑇 = 𝑉1 + 𝑉2 + 𝑉3 + 𝑉4 + ⋯ + 𝑉𝑛−1 + 𝑉𝑛 , (5)

𝑑
(𝑉𝑇 − 𝑉1 ) − (𝑛 − 1)𝐿𝑚 𝑖
𝑑𝑡 1 = 𝑑 (𝑖 + 𝑖 + ⋯ + 𝑖 ). (6)
𝐿𝑠 + (𝑛 − 2)𝐿𝑚 𝑑𝑡 2 3 𝑛

The voltages developed across each winding can be

represented by the self and mutual inductance terms. The Figure 7. Switch mode and inductor current
complete voltage equations for n-winding are expressed in under the n-winding coupled inductor
matrix format, as shown in (4). In (5), the sum of all 1 + (𝑛 − 2)𝑘 − (𝑛 − 1)𝑘 2 𝑑
winding voltages is defined as 𝑉𝑇 . The sum of the (2nd 𝑉1 = 𝐿𝑠 𝑖1 , (10)
𝐷 𝑑𝑡
1 + (𝑛 − 1 − 𝑝(𝑡))𝑘 + (𝑛 − 𝑝(𝑡)) 𝑘
through nth) row of (4) can be expressed as in (6) using 𝑉𝑇 1−𝐷
of (5). Applying (6) to the 1st row of (4) and employing (3)
1 + 𝑘 − 2𝑘 2 𝑑
results in (7) after simplification: 𝑉1 = 𝐿𝑠
𝐷
𝑖1
1 + (2 − 𝑝(𝑡))𝑘 + (3 − 𝑝(𝑡)) 𝑘 𝑑𝑡
1−𝐷 (11)
2)
𝑑
(1 + (𝑛 − 1)𝑘)𝑉1 − 𝑘𝑉𝑇 = 𝐿𝑠 (1 + (𝑛 − 2)𝑘 − (𝑛 − 1)𝑘 𝑖 , (7) under 𝑛 = 3 .
𝑑𝑡 1
In equation (10), the operation of each dc-dc converter
(1 + 2𝑘)𝑉1 − 𝑘(𝑉1 + 𝑉2 + 𝑉3 ) module is assumed to be under continuous conduction
𝑑 (8)
= 𝐿𝑠 (1 + 𝑘 − 2𝑘 2 ) 𝑖 under 𝑛 = 3. mode. The general industrial design rule often states that
𝑑𝑡 1
Equation (8) is the example case of the 3-winding during a heavy load condition, a dc-dc converter remains
coupled inductor (n =3) based on the general form of (7). in continuous conduction operating mode (CCM).
Therefore, the assumption of the continuous conduction
mode adopted in (10) while investigating the operation of
III. SELECTION OF OPTIMAL COUPLING FACTOR FOR THE coupled inductor with respect to maximum current stress
COUPLED INDUCTOR can be accepted. Equation (10) is transformed into the
simpler form of (12) with the introduction of the
In this section, the employed model of the n-winding Equivalent Inductance (𝐿𝑒𝑞 ) It is noted from (12) that the
coupled inductor as described in (7) is further utilized to equivalent inductance ( 𝐿𝑒𝑞 ) depends on the self-
investigate the operation of the n-winding coupled
inductance (𝐿𝑠 ), number of phase (n), coupling factor (k),
inductor in multi-phase interleaved half-bridge topology,
duty ratio (D), and the newly defined function, p(t).
as shown in Fig. 2. In (7), the winding voltages ( 𝑉1 ,
Therefore, the equivalent inductance 𝐿𝑒𝑞 (𝑡) of the
𝑉2 ,…𝑉𝑛 , and 𝑉𝑇 ) of the multi-legged inductor depend on
the switching states of the switches that are connected with coupled inductor is a function of time, in which, its
the corresponding phase winding, i.e. ( 𝑆𝑊1 , 𝑆𝑊2 ,… functional value is determined by the switching states.
𝑆𝑊𝑛 ). In order to describe the switching states of all Figure 7 shows the variations of inductor voltage 𝑉1 and
switches in a systematic and simplified manner, a new equivalent inductance 𝐿𝑒𝑞 (𝑡) depending on the switching
variable of p(t) is introduced in this paper. This variable of states in the case of n-winding coupled inductor provided
p(t) is defined to be the total number of switches being by (11):
turned on while one pivotal switch is turned on at time t.
𝑑
For the sake of simplicity, 𝑆𝑊1 is selected as the pivotal 𝑉1 = 𝐿𝑒𝑞 (𝑡) 𝑖 . (12)
𝑑𝑡 1
switch. A clear representation of the relationship between
The coupled inductor turns off to have a variable
equivalent inductance 𝐿𝑒𝑞 (𝑡) , depending on the

245
corresponding time interval during each switching cycle. 𝑉𝑖𝑛 − 𝑉𝑜 𝑚
∆𝑖|𝑝(𝑡)=𝑚 = ( − 𝐷) 𝑇𝑠 . (18)
This variable equivalent inductance can be either smaller 𝐿𝑒𝑞 |𝑝(𝑡)=𝑚 𝑛
or larger than the self-inductance (𝐿𝑠 ), depending on the
Equations (19)–(21) successfully are derived to present
value of the duty ratio (D) and the coupling factor (k).
the explicit form of the total peak-to-peak ripple size of
Therefore, the rising or falling slope of the inductor current
inductor current for the generalized case of the n-winding
also varies with respect to the corresponding equivalent
coupled inductor.
inductance. Figure 7 presents the waveform of the inductor
current of phase-1 under the example in terms of the n- 𝑉𝑖𝑛 𝑇𝑠 𝑚 𝑚−1
∆𝑖𝐿 = (1 − 𝐷) {𝐴 ∙ (𝑚 − 1) ( − 𝐷) + 𝐵 ∙ 𝑚 ∙ (𝐷 − )} , (19)
𝐿𝑠 𝑛 𝑛
winding coupled inductor. Note from this inductor current
𝐷
waveform that the total peak-to-peak ripple size of the 1 + (𝑛 − 𝑚)𝑘 + (𝑛 − 𝑚 + 1)
1−𝐷 ,
𝑘
A= (20)
inductor current (𝑖1 ) can be represented by the sum of 1 + (𝑛 − 2)𝑘 − (𝑛 − 1)𝑘 2
several incremental terms, depending on the equivalent
𝐷
inductance and time duration of the particular switching 1 + (𝑛 − 1 − 𝑚)𝑘 + (𝑛 − 𝑚)
1−𝐷 .
𝑘
(21)
B=
time interval. 1 + (𝑛 − 2)𝑘 − (𝑛 − 1)𝑘 2

𝑉𝑖𝑛 − 𝑉𝑜 Equations (22) and (23) are also derived from Eqs.
∆𝑖Lpp = 𝐷𝑇 . (13)
𝐿𝑒𝑞 (19)–(21) under the example case of 3-winding (n= 3) and
Equation (13) is basic equation of inductor current m = 1 at duty interval of (0 < D < 1/3).
ripple under rising interval of inductor current in dc-dc 𝐷
1 + (3 − 1)𝑘 + (3 − 1 + 1) 𝑘
converters. In Eq. (13), Switch turn on time (DT) need to A= 1−𝐷
be generalized for simplify equation of generalized n- 1 + (3 − 2)𝑘 − (3 − 1)𝑘 2
(22)
phase coupled inductor current ripples as follows, 1
under (𝑛 = 3 and 0 < D < (𝑚 = 1)) ,
3
𝑚−1 𝐷
𝐷𝑇|p(t)=𝑚−1 = (𝐷 − )𝑇 , (14) 1 + (3 − 1 − 1)𝑘 + (3 − 1) 𝑘
𝑛 B= 1−𝐷
1 + (3 − 2)𝑘 − (3 − 1)𝑘 2
𝑚 (23)
𝐷𝑇|p(t)=𝑚 = ( − 𝐷) 𝑇 . (15) 1
𝑛 under (𝑛 = 3 and 0 < D < (𝑚 = 1)) .
3
In equation (14) and (15), the new parameter of (m) is
Equations (19)–(21) are used in Eqs. (24)–(27) to derive
defined. The value of (m) shows determined by the duty
ratio (D). Figure 8 explains the relationship between (m) the optimized coupling factor (𝑘𝑜𝑝𝑡 ), which generates the
and the duty ratio (D) in n-phase interleaved dc-dc minimum value of the peak-to-peak ripple size of inductor
converter. This new parameter (m) can be simplifies the current. Note from Eqs. (24)–(27) that this optimized
calculation steps of obtaining the total number of coupling factor (𝑘𝑜𝑝𝑡 ) is a function of the duty ratio (D),
switching time intervals having the same value of number of phase (n), and newly defined parameter of (m).
equivalent inductance, i.e. rising slope of inductor current. Equations (24)–(27) can lead to a simpler design of the
m
coupled inductor that minimizes the current stress imposed
n
n-1 on the coupled inductor. Equations (28)–(30) give the
optimal coupling factor ‘k’ for minimum inductor current
...

...
5
4
ripple under the example case of 3-winding (n = 3) at
3
2 different duty intervals (m = 1, 2, 3), respectively.
1 Duty ratio

1/n 2/n 3/n 4/n ... (n-2)/n (n-1)/n 1

𝑌 + √𝑌 2 − 𝑋𝑍
𝑘𝑜𝑝𝑡 = 𝑓(𝐷, 𝑛, 𝑚) = , (24)
Figure 8. Relationship between ‘m’ and the duty ratio (D) of the n- 𝑋
phase coupled inductor.
m X = (𝑛2 − 𝑛)𝐷2 + (−2𝑚𝑛2 + 2𝑚𝑛 + 𝑛3 − 𝑛2 )𝐷 + 𝑚2 𝑛 − 𝑚2 − 𝑚𝑛 + 𝑚 , (25)

3 Y = (𝑛2 − 𝑛)𝐷2 − (𝑛2 − 𝑛)𝐷 , (26)

2

Z = (𝑛2 − 𝑛)𝐷2 + (2𝑛 − 2𝑚𝑛)𝐷 + 𝑚2 − 𝑚 , (27)

1

Duty rati o
6𝐷2 − 6𝐷 + √(6𝐷2 − 6𝐷)2 − (6𝐷2 + 6𝐷)6𝐷2
1/3 2/3 1 𝑘𝑜𝑝𝑡 =
6𝐷2 + 6𝐷
Figure 9. Relationship between ‘m’ and the duty ratio (D) of the 3- 1 (28)
under (𝑛 = 3 and 0 < D < (𝑚 = 1)) ,
phase coupled inductor (n = 3). 3

Form interval value (m) and (14) and (15), current ripple
of n-phase coupled inductor in rising slope interval can be 𝑘𝑜𝑝𝑡 =
6𝐷2 − 6𝐷 + √(6𝐷2 − 6𝐷)2 − (6𝐷2 − 6𝐷 + 4)(6𝐷2 − 6𝐷 + 2)
6𝐷2 − 6𝐷 + 4
expressed as follows, 1 2 (29)
under (𝑛 = 3 and < D < (𝑚 = 2)) ,
3 3
∆𝑖L = (𝑚)∆𝑖|𝑝(𝑡)=𝑚−1 + (𝑚 − 1)∆𝑖|𝑝(𝑡)=𝑚 , (16)
𝑉𝑖𝑛 − 𝑉𝑜 𝑚−1 6𝐷2 − 6𝐷 + √(6𝐷2 − 6𝐷)2 − (6𝐷2 − 18𝐷 + 12)(6𝐷2 − 12𝐷 + 6)
∆𝑖|𝑝(𝑡)=𝑚−1 = (𝐷 − ) 𝑇𝑠 , (17) 𝑘𝑜𝑝𝑡 =
𝐿𝑒𝑞 |𝑝(𝑡)=𝑚−1 𝑛 6𝐷2 − 18𝐷 + 12
(30)
2
under (𝑛 = 3 and < D < 1 (𝑚 = 3)) .
3

246
 IV. APPLICATION OF THE PROPOSED COUPLING FACTOR that the current ripple is smaller than the non-coupled
EQUATION TO THE TRACTION BATTERY CHARGING inductor. The coupling factor is -0.3. When duty ratio
SYSTEM changes from 0.4 to 0.46 based on Table II, the current
ripple P.U value enters negative section in Fig. 10. In this
In this paper, the proposed design rule of the optimal situation, the inductor current ripple becomes smaller than
coupling factor is based on specific duty cycle value of the the non-coupled inductor current ripple so that the coupled
dc-dc converter. Therefore, when the duty cycle is outside inductor ripple reduction effect can be obtained. In
this specific range, the benefit of the minimum ripple size addition, decreasing the duty ratio to 0.3 by increasing dc
of the inductor current may not be achieved. However, in link voltage can provide a better coupling effect. However,
most of the application cases for dc-dc converters, the duty this is not an appropriate design for high power rapid
cycle for the maximum ripple size of inductor current is electric vehicle charging system.
either fixed or limited within a relatively narrow band.
Particularly, in the case of battery charging applications,
the maximum stress of the inductor current is usually
encountered during Constant Current charging mode,
under which the duty cycle is limited within a relatively
narrow band. So, by selecting the optimal coupling factor
corresponding to this representative duty cycle value, the
current stress of the inductor under the worst operating
condition could be minimized. Therefore, as for the
applications that have a relatively narrow range of duty Figure 10. Inductor current ripple ratio of 3-winding vs. duty
cycle, the proposed design rule of the optimal coupling ratio under coupling factor -0.3
factor would decrease the maximum and worst ripple size
of the inductor current. V. SYSTEM VERIFICATION
In the EV charging platform, the Coupled inductor TABLE III. SPECIFICATIONS FOR VERIFICATION TEST.
design is based on the duty ratio in the dc-dc converter. Parameter HILS Hardware experiment
The typical charging operation SOCs for rapid EV
Input voltage 200 V 200 V
charging systems have a range of (20 to 80) %. In the range,
Self inductance 1 mH 1 mH
the rapid EV charging system operates in constant current
Coupling factor 0 – -0.5 -0.3
mode. Table II shows the battery specification of electric
Duty ratio 0 – 0.9 0.2 and 0.5
vehicle batteries of renowned automotive brands. In
Output Capacitance 330 uF 330 uF
Table II, the rapid charging system duty ratio range in
constant current mode changes from (0.4 to 0.46). The
This section presents the simulation and experimental
extent of the duty ratio change is not large.
results for the proposed mathematical formula of the
TABLE II. BATTERY SPECIFICATION OF ELECTRIC TRACTION optimal coupling factor. Simulation and experimental
BATTERY
verification are performed with the 3-winding coupled
Battery Duty ratio
Rated Pack
Min/Max voltage range range inductor in 3-phase staggered dc-dc converter modules.
Energy /
Brand Battery
Capacity /
Cell between SOC between The influence of 3-winding coupled inductors having
Voltage[V] 20% and 80% SOC 20%
Cell
[V] and 80% 1)
different coupling factors on the ripple size of inductor
2015
current is investigated and compared with that of
LG Chem 18.4 kWh /
Chevrolet
Lithium-ion 52.0 Ah / 96
3.00/4.15 340 ~ 380 0.40 ~ 0.45 theoretical model. Table III shows the test specifications
Spark for hardware and simulation verification.
2013
AESC 24.0 kWh /
Nissan 2.50/4.20 290 ~ 345 0.40 ~ 0.46
Lithium-ion 66.2 Ah / 96
Leaf S
2013
Samsung SDI 18.8 kWh /
Nissan 2.70/4.10 340 ~ 380 0.40 ~ 0.45
Lithium-ion 60.0 Ah / 96
Leaf S
SK
2015 Kia 27.0 kWh /
Innovation 2.50/4.30 345 ~ 380 0.40 ~ 0.45
Soul 75.0 Ah / 96
Lithium-ion
1 ) Duty ratio ranges are calculated to use dc_link voltage 850V in
proposed rapid EV charging system as shown Fig. 1
Figure 11. Hardware-in-the-loop Figure 12. Hardware test
Figure 10 presents the verified relationship between simulation set-up for coupled inductor set-up for coupled inductor
duty ratio and ratio of inductor current ripple in non- testing. testing.
coupled inductor and coupled inductor in section Ⅴ. In this
paper, the coupling factor is designed to be -0.3 based on
Fig. 17 under duty ratio of 0.4. In Fig. 10, the negative
value is the section of coupled inductor current ripple
which is less than the non-coupled inductor current ripple.
It maybe noted that using coupled inductor does not mean

247
 TABLE Ⅳ. COMPARISON OF COUPLED INDUCTOR ratio of 0.3, 0.5, and the coupling factor of -0.3 (inverse
(NON-COUPLED, 2-WINDING, 3WINDING) coupling) in three phase-staggered operation of the battery
charging unit of Fig. 2.
2-winding coupled 3-winding coupled
Non-coupled
inductor inductor

Photo

Structure

50*15*30*2 70*15*30*2 =
15*130*30*2 = Figure 13. Simulation waveforms Figure 14. HIL simulation
117,000 [mm3]
Core
= 45,000 [mm3] 63,000 [mm3]
15*60*30*3 = of non-coupled inductor current waveforms of
Volume
40*15*30*2 60*15*30*3 =
81,000 [mm3] under duty = 0.3 non-coupled inductor current
= 36,000 [mm3] 81,000 [mm3]
7.5*60*30*2 = and coupling factor = 0. under duty = 0.3
27,000 [mm3]
Volume and coupling factor = 0
per 81,000 [mm3] 72,000 [mm3] 75,000 [mm3] (𝑖1 , 𝑖2 ,𝑖3 [2 A/div, 50 µs/div]).
winding

Table Ⅳ gives structural and dimensional comparison

of non-coupled, 2-winding coupled, and 3-winding
coupled inductor. Coupled inductors in the inductor
structure share the mutual flux through the center leg,
which is shown in Table Ⅳ. The 2-winding coupled
inductor has a center leg in the middle for coupling factor.
The coupling factor is controlled by controlling the air gap
of the center leg. As the air gap length increases, the
leakage flux decreases and the mutual flux increases,
consequently the value of the coupling factor increases.
An important element in coupled-inductor design is that Figure 15. HIL simulation Figure 16. Experiment waveforms of
waveforms of coupled inductor current
flux must be balanced. For that reason, the multi-winding coupled inductor current under duty = 0.3
coupled inductor design concept for balancing was under duty = 0.5 and coupling and coupling factor = -0.3
proposed in Fig. 3. However, due to the lack of the factor = -0.3 (𝑖1 , 𝑖2 , 𝑖3 [1A/div, 20 µs/div]).
resources, the structure of the inductor core was modified (𝑖1 , 𝑖2 , 𝑖3 [2.5A/div, 50 µs/div]).
to design the 3-winding coupled inductor structure as In order to validate the theoretical model of the multi-
shown in Fig. 4. This structure is advantageous as the winding coupled inductor and its optimized coupling
magnetic flux balance of the 3-winding coupled inductor factor for the minimal current ripple as described in Eqs.
can be made constant by the metal core. The disadvantage (28)–(30), the peak-to-peak inductor current ripple is
is the increase in volume due to additional center leg. measured from the test set-up under the variation of both
However, in volume per winding, of the 3-winding duty cycle and coupling factor. Figures 17-19 shows the
coupled inductor is smaller than the non-coupled inductor. total peak-to-peak inductor current ripple versus coupling
Figures 13-16 show the simulation and experiment factor at a specific duty ratio. The data line represents the
waveforms of the switching function and 3-winding values calculated from the mathematical model of the
coupled inductor currents (𝑖1 , 𝑖2 , and 𝑖3 ) under the duty coupled inductor, i.e. Eqs. (19)–(21). The dotted data
1.5 1.5 1.5

D=0.1 ( ■ )
D=0.2 ( Ж ) D=0.4 ( ■ ) 1.4
D=0.7 ( ■ )
1.4 1.4
D=0.3 ( ) D=0.5 ( Ж ) D=0.8 ( Ж )
D=0.6 ( ) D=0.9 ( )

1.3 1.3 1.3

Inductor current ripple [P.U]

Inductor current ripple [P.U]

Inductor current ripple [P.U]

1.2 1.2 1.2

1.1 1.1 1.1

1 1 1

0.9 0.9 0.9

0.8 0.8 0.8

0.7 0.7 0.7

0.45 0.4 0.35 0.3 0.25 0.2 0.15 0.1 0.05 0 0.45 0.4 0.35 0.3 0.25 0.2 0.15 0.1 0.05 0 0.45 0.4 0.35 0.3 0.25 0.2 0.15 0.1 0.05 0

Coupling factor [k] Coupling factor [k] Coupling factor [k]

Figure 17. Inductor current ripple Vs. coupling Figure 18. Inductor current ripple Vs. coupling Figure 19. Inductor current ripple Vs. coupling
factor data waveform under 0 < D < 1/3 factor data waveform under 1/3 < D < 2/3 factor data waveform under 2/3 < D < 1
[line : math. analysis, dot : HIL simulation] [line : math. analysis, dot : HIL simulation] [line : math. analysis, dot : HIL simulation]

248
points represent the measurement values from the
experimental set-up employing the coupled inductor
model from HILS. Note that in these figures, the
experimental data closely follow the pattern of the
theoretical curve.
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7
-0.1
-0.2
-0.3
-0.4
-0.5
-0.6
3-winding
-0.7
-0.8
2-winding
-0.9
1 k
Figure 20. Multi-winding optimizing coupling factor of
the minimum inductor current ripple (𝑘𝑜𝑝𝑡 ) vs. duty ratio.
In Figs. 17-19, it is interesting to observe that there is a
specific coupling factor value at which the inductor current
ripple reaches the minimum value. Figure 20 shows these
specific coupling factor values for the minimum inductor
current ripple obtained from Figs. 17-19 under the
condition of various duty ratio values. Figure 20 confirms
that the experimental data of the optimal coupling factor
(𝑘𝑜𝑝𝑡 ) vs. duty ratio match those of the theoretical curve,
which is calculated from the mathematical model of Eqs.
(24)–(27). The comparison is carried out for the cases of
the (2, 3, 4, and 5)-winding coupled inductor, respectively.
Note in Fig. 20 that as the duty ratio approaches (1/n, 2/n,
…, n-1/n), the optimal coupling factor value becomes -
1/(n-1), i.e. inverse coupling without leakage inductances.
The graph shown in Fig. 20 can be utilized as a useful
design guideline to select the optimal coupling factor in a
Battery Charging Unit employing the n-winding coupled
inductor. In fact, when the duty cycle varies, the benefit of
the minimum ripple size of the inductor current may not be
achieved. However, in most of the application cases for dc-
dc converters, the duty cycle for the maximum ripple size
of inductor current is either fixed or limited within a
relatively narrow band. Particularly, in the case of battery
charging applications, the maximum stress of the inductor
current is usually encountered during Constant Current
charging mode, under which the duty cycle is limited
within a relatively narrow band. So, by selecting the
optimal coupling factor corresponding to this
representative duty cycle value as shown in Fig. 20, the
current stress of the inductor under the worst operating
condition could be minimized. Therefore, as for the
applications that have a relatively narrow range of duty
cycle, the proposed design rule of optimal coupling factor
would decrease the maximum and worst ripple size of the
inductor current.
VI. CONCLUSION
Magnetic coupling of multiple inductors in paralleled
dc-dc converters including buck converters is widely used
in a variety of power electronics applications. Battery
charging dc-dc converter is one of these application. The
optimal distribution of leakage and magnetic inductance in
the coupled inductors is a demanding engineering task.
This paper proposes a novel idea to design the optimal
coupling factor of a coupled inductor having multiple
windings. Based on the newly proposed mathematical
0.8 0.9 1
modeling and approach for a general n-winding coupled
Duty inductor, the value of optimal coupling factor
corresponding to the minimum value of inductor current
5-winding ripple is obtained. It was found that this optimal coupling
4-winding factor depended on the duty ratio of dc-dc converter under
steady-state condition. This paper propose a design rule for
coupled inductor based on coupled inductor modeling
theory. Non-coupled inductors and coupled inductors with
the same self-inductance were designed and compared.
The coupled inductors have smaller volume per winding
than non-coupled inductors. Experimental results based on
the HILS setup successfully confirmed that this newly
proposed method could be used to obtain the optimal
coupling factor. In conclusion, by applying coupled
inductor, the inductor current ripple can be reduced, higher
design margin can be obtained, and the hardware design of
the system will be easy due to the size reduction of the
inductor.
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