Accurate Efficiency and Power Densities Optimization of Output Inductor of Buck Derived Converters

In this article, inductor loss models are developed based on the experimental characterization of off-the-shelf components. The modelling steps and techniques are described and validated. It is shown that the model exhibits fairly good accuracy over a large range of ripple current frequency and magnitude. Then, these models are used, as an illustration, in order to present the possible optimization process of the tradeoff between switching frequency-current ripple magnitude and output inductors value in the case of a Buck-derived converter. This optimization has shown that a large current ripple may lead to minimized losses in some cases. The developed modelling technique aims to represent Joules and iron losses, as well as DC and AC losses of inductors. It is not based on physical behaviour description but on mathematical equations based on a set of experimental characterizations. The modelling technique is not suitable for designing the component itself but is useful for selecting the best component value in the manufacturer's series of components. Since it remains difficult with the manufacturer datasheet to estimate AC losses accurately with respect to frequency and ripple current magnitude, a specific characterization is carried out to complement the available data.