An Accurate Calculation Method for Inductor Air Gap Length in High Power DC-DC Converters

An Accurate Calculation Method for Inductor Air Gap Length in High Power DC-DC Converters | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Article An Accurate Calculation Method for Inductor Air Gap Length in High Power DC-DC Converters Xiaohui Zeng, Wei Chen, Lei Yang, Qingbin Chen, Yuping Huang This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-3820495/v1 This work is licensed under a CC BY 4.0 License Status: Published Journal Publication published 12 Feb, 2024 Read the published version in Scientific Reports → Version 1 posted 8 You are reading this latest preprint version Abstract High-power inductors are fundamental components in high-power DC-DC converters, with their performance being a crucial metric of converter efficiency. This paper presents an in-depth analysis of a novel calculation method for the air gap length in such inductors. Taking into account the effects of air gap diffusion and the winding magnetic field, an expression for the air gap diffusion radius is derived, focusing on a distributed air gap structure. Furthermore, models for calculating the air gap and winding reluctance are developed, grounded in electromagnetic field theory. An equivalent magnetic circuit model, formulated based on Kirchhoff's second law, facilitates the proposed method for air gap length calculation. This study also involves the development of 3D models for both discrete and decoupled integrated inductors. The comparison between simulation outcomes and calculated air gap lengths indicates a maximum error of less than 5%, with the minimum error being as low as 0.54%. Additionally, the discrepancy between calculated values and experimental measurements is found to be 1.11%. These results validate the accuracy and applicability of the theoretical analysis and calculation method, underscoring their significance in the design and optimization of high-power DC-DC converters. Physical sciences/Engineering/Electrical and electronic engineering Physical sciences/Engineering Full Text Additional Declarations No competing interests reported. Cite Share Download PDF Status: Published Journal Publication published 12 Feb, 2024 Read the published version in Scientific Reports → Version 1 posted Editorial decision: Revision requested 12 Jan, 2024 Reviews received at journal 10 Jan, 2024 Reviewers agreed at journal 31 Dec, 2023 Reviewers invited by journal 31 Dec, 2023 Editor assigned by journal 31 Dec, 2023 Editor invited by journal 30 Dec, 2023 Submission checks completed at journal 30 Dec, 2023 First submitted to journal 29 Dec, 2023 You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. As a division of Research Square Company, we’re committed to making research communication faster, fairer, and more useful. We do this by developing innovative software and high quality services for the global research community. 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Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-3820495","acceptedTermsAndConditions":true,"allowDirectSubmit":false,"archivedVersions":[],"articleType":"Article","associatedPublications":[],"authors":[{"id":264734337,"identity":"b6ef00ec-7fe7-41ab-bf95-86f4353eac18","order_by":0,"name":"Xiaohui Zeng","email":"","orcid":"","institution":"Fuzhou University","correspondingAuthor":false,"submittingAuthor":false,"prefix":"","firstName":"Xiaohui","middleName":"","lastName":"Zeng","suffix":""},{"id":264734338,"identity":"72777832-802f-41f8-b054-fc36eac5bef4","order_by":1,"name":"Wei Chen","email":"","orcid":"","institution":"Fuzhou University","correspondingAuthor":false,"submittingAuthor":false,"prefix":"","firstName":"Wei","middleName":"","lastName":"Chen","suffix":""},{"id":264734339,"identity":"647da777-c398-4b6e-98de-066d97cea409","order_by":2,"name":"Lei Yang","email":"","orcid":"","institution":"Beijing Institute of Precision Mechatronics and Controls","correspondingAuthor":false,"submittingAuthor":false,"prefix":"","firstName":"Lei","middleName":"","lastName":"Yang","suffix":""},{"id":264734340,"identity":"a7f384aa-3a69-43ef-857c-99ceeed6d5eb","order_by":3,"name":"Qingbin Chen","email":"data:image/png;base64,iVBORw0KGgoAAAANSUhEUgAAAZAAAAAyAQMAAABI0h/eAAAABlBMVEX///8AAABVwtN+AAAACXBIWXMAAA7EAAAOxAGVKw4bAAAAo0lEQVRIiWNgGAWjYFACHsYHFWBGAvFamA3OkKqFTYI0LfztuccqDvw5zMDPnmPA8HMHEVokzrxLu3GA5zCDZM8bA8beM0RoMZDIMbv9QeIwg8GNHANmxjYitRQcMDjMYE+SFoYDCYdBDCK1AP2SLHHgQDqPxJlnBQd7idECDLGDHw78sZbjb0/e+OAnMVpg0cEDIg4QpYGUSB8Fo2AUjIKRCgDObzVTWoDF2QAAAABJRU5ErkJggg==","orcid":"","institution":"Fuzhou University","correspondingAuthor":true,"submittingAuthor":false,"prefix":"","firstName":"Qingbin","middleName":"","lastName":"Chen","suffix":""},{"id":264734341,"identity":"3913ee72-559e-413a-b524-b2d669c56a86","order_by":4,"name":"Yuping Huang","email":"","orcid":"","institution":"Beijing Institute of Precision Mechatronics and Controls","correspondingAuthor":false,"submittingAuthor":false,"prefix":"","firstName":"Yuping","middleName":"","lastName":"Huang","suffix":""}],"badges":[],"createdAt":"2023-12-29 09:14:22","currentVersionCode":1,"declarations":"","doi":"10.21203/rs.3.rs-3820495/v1","doiUrl":"https://doi.org/10.21203/rs.3.rs-3820495/v1","draftVersion":[],"editorialEvents":[{"content":"https://doi.org/10.1038/s41598-024-54194-7","type":"published","date":"2024-02-12T15:01:05+00:00"}],"editorialNote":"","failedWorkflow":false,"files":[{"id":51322877,"identity":"74a0e74a-dc97-4375-879d-9821e06b2fa0","added_by":"auto","created_at":"2024-02-19 15:12:46","extension":"pdf","order_by":1,"title":"","display":"","copyAsset":false,"role":"manuscript-pdf","size":489192,"visible":true,"origin":"","legend":"","description":"","filename":"Manuscript.pdf","url":"https://assets-eu.researchsquare.com/files/rs-3820495/v1_covered_4315b6a0-25df-43f3-9891-cca351cef035.pdf"}],"financialInterests":"No competing interests reported.","formattedTitle":"An Accurate Calculation Method for Inductor Air Gap Length in High Power DC-DC Converters","fulltext":[],"fulltextSource":"","fullText":"","funders":[],"hasAdminPriorityOnWorkflow":false,"hasManuscriptDocX":false,"hasOptedInToPreprint":true,"hasPassedJournalQc":"","hasAnyPriority":false,"hideJournal":false,"highlight":"","institution":"","isAcceptedByJournal":true,"isAuthorSuppliedPdf":true,"isDeskRejected":"","isHiddenFromSearch":false,"isInQc":false,"isInWorkflow":false,"isPdf":true,"isPdfUpToDate":true,"isWithdrawnOrRetracted":false,"journal":{"display":true,"email":"[email protected]","identity":"scientific-reports","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":false,"externalIdentity":"scirep","sideBox":"Learn more about [Scientific Reports](http://www.nature.com/srep/)","snPcode":"","submissionUrl":"","title":"Scientific Reports","twitterHandle":"","acdcEnabled":true,"dfaEnabled":true,"editorialSystem":"stoa","reportingPortfolio":"Scientific Reports","inReviewEnabled":true,"inReviewRevisionsEnabled":true},"keywords":"","lastPublishedDoi":"10.21203/rs.3.rs-3820495/v1","lastPublishedDoiUrl":"https://doi.org/10.21203/rs.3.rs-3820495/v1","license":{"name":"CC BY 4.0","url":"https://creativecommons.org/licenses/by/4.0/"},"manuscriptAbstract":"\u003cp\u003eHigh-power inductors are fundamental components in high-power DC-DC converters, with their performance being a crucial metric of converter efficiency. This paper presents an in-depth analysis of a novel calculation method for the air gap length in such inductors. Taking into account the effects of air gap diffusion and the winding magnetic field, an expression for the air gap diffusion radius is derived, focusing on a distributed air gap structure. Furthermore, models for calculating the air gap and winding reluctance are developed, grounded in electromagnetic field theory. An equivalent magnetic circuit model, formulated based on Kirchhoff's second law, facilitates the proposed method for air gap length calculation. This study also involves the development of 3D models for both discrete and decoupled integrated inductors. The comparison between simulation outcomes and calculated air gap lengths indicates a maximum error of less than 5%, with the minimum error being as low as 0.54%. Additionally, the discrepancy between calculated values and experimental measurements is found to be 1.11%. These results validate the accuracy and applicability of the theoretical analysis and calculation method, underscoring their significance in the design and optimization of high-power DC-DC converters.\u003c/p\u003e","manuscriptTitle":"An Accurate Calculation Method for Inductor Air Gap Length in High Power DC-DC Converters","msid":"","msnumber":"","nonDraftVersions":[{"code":1,"date":"2024-01-03 18:07:43","doi":"10.21203/rs.3.rs-3820495/v1","editorialEvents":[{"type":"communityComments","content":0},{"type":"decision","content":"Revision requested","date":"2024-01-12T11:42:05+00:00","index":"","fulltext":""},{"type":"editorInvitedReview","content":"","date":"2024-01-10T15:02:38+00:00","index":"hide","fulltext":""},{"type":"reviewerAgreed","content":"9e358143-abc7-4252-902e-912af2ec2146","date":"2024-01-01T03:31:31+00:00","index":"hide","fulltext":""},{"type":"reviewersInvited","content":"","date":"2023-12-31T18:48:13+00:00","index":"","fulltext":""},{"type":"editorAssigned","content":"","date":"2023-12-31T18:34:51+00:00","index":"","fulltext":""},{"type":"editorInvited","content":"","date":"2023-12-30T17:39:42+00:00","index":"","fulltext":""},{"type":"checksComplete","content":"","date":"2023-12-30T17:38:46+00:00","index":"","fulltext":""},{"type":"submitted","content":"Scientific Reports","date":"2023-12-29T09:09:22+00:00","index":"","fulltext":""}],"status":"published","journal":{"display":true,"email":"[email protected]","identity":"scientific-reports","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":false,"externalIdentity":"scirep","sideBox":"Learn more about [Scientific Reports](http://www.nature.com/srep/)","snPcode":"","submissionUrl":"","title":"Scientific Reports","twitterHandle":"","acdcEnabled":true,"dfaEnabled":true,"editorialSystem":"stoa","reportingPortfolio":"Scientific Reports","inReviewEnabled":true,"inReviewRevisionsEnabled":true}}],"origin":"","ownerIdentity":"7077281b-90cc-413c-8fd1-4aaa93086dd6","owner":[],"postedDate":"January 3rd, 2024","published":true,"recentEditorialEvents":[],"rejectedJournal":[],"revision":"","amendment":"","status":"published-in-journal","subjectAreas":[{"id":27894341,"name":"Physical sciences/Engineering/Electrical and electronic engineering"},{"id":27894342,"name":"Physical sciences/Engineering"}],"tags":[],"updatedAt":"2024-02-19T15:05:30+00:00","versionOfRecord":{"articleIdentity":"rs-3820495","link":"https://doi.org/10.1038/s41598-024-54194-7","journal":{"identity":"scientific-reports","isVorOnly":false,"title":"Scientific Reports"},"publishedOn":"2024-02-12 15:01:05","publishedOnDateReadable":"February 12th, 2024"},"versionCreatedAt":"2024-01-03 18:07:43","video":"","vorDoi":"10.1038/s41598-024-54194-7","vorDoiUrl":"https://doi.org/10.1038/s41598-024-54194-7","workflowStages":[]},"version":"v1","identity":"rs-3820495","journalConfig":"researchsquare"},"__N_SSP":true},"page":"/article/[identity]/[[...version]]","query":{"redirect":"/article/rs-3820495","identity":"rs-3820495","version":["v1"]},"buildId":"WrCJVZZCHTDjtuVLN7oU0","isFallback":false,"isExperimentalCompile":false,"dynamicIds":[84888],"gssp":true,"scriptLoader":[]}