A Practical Approach for Core Loss Estimation of a High-Current Gapped Inductor in PWM Converters With a User-Friendly Loss Map

Core loss estimation of filter inductors is increasingly important for modeling and optimizing high-frequency, high-efficiency, and high-density pulsewidth modulation (PWM) power electronic converters. However, data provided by inductor core manufacturers are insufficient for core loss estimation in PWM converters, particularly in the case of customized gapped inductors. This paper presents a whole process of characterizing and estimating the core loss of a customized high-current gapped inductor for PWM converters. To excite the inductor for the B-H loop measurement, a test circuit formed by a half-bridge structure is proposed, which has the ability to compensate the asymmetric rectangular voltage on the inductor caused by the device voltage drops. To overcome the other challenges raised by a high excitation current, a refined discontinuous test procedure, triple pulse test, is proposed to reduce the requirements of the high-current test setup (thermal stress, current-time stress for current probes, capacity of dc sources, etc.). For practical purposes, a user-friendly loss map approach is proposed involving only time-domain and electrical variables to replace magnetic variables to enable the straightforward loss mapping process and core loss calculations. Presented experimental results show consistency between the estimated inductor loss and measured values. Overall, the proposed testing approach can be easily implemented on the user's side to develop a loss map of a given inductor. The established core loss map enables the users to accurately and rapidly estimate the core loss of a tested inductor for given PWM waveforms.