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TIDA-00779: PFC Inductor power loss issue

vasudev mr
Prodigy 80 points
Part Number: TIDA-00779

Hi,

I am Vasudev here. I observed in the reference design that pfc inductor is wound with single strand copper wire. If the pfc is operating at 65khz ,even if the current ripple is minimum wont there be skin effect present and  I have also observed in the reference design that thermal imaging shows that inductor temperature is not very high(which says skin effect is not prominent). But I am facing inductor heating issue . I am using iron power core with single strand winding . so my question is , is it skin effect or core loss which is heating up the core? 

power - 1.8kw

peak current of inductor - 8 amps max

I am using 1.8mm thick copper wire. 

pfc inductance - 450u at no load . Inductor will saturate at 13 amps. 

thank you  

  • 0
    TI__Intellectual 830 points

    Hi, Vasudev

    based on your design, 450uH at no load with iron power core, here are our comments

    1. What is the inductance at peak AC current?
    2. Iron power material has higher core loss compare to other material, especially at high switching frequency. Skin effect contribution is not so big here.
    3. What's your designed ripple current percentage? have you tested inductor peak ripple current? High ripple current will make Iron power core loss bigger.
    4. Suggest to try other core material, such as KoolMu, or MPP.

    Regards

    Hely

  • +1 in reply to Hely Zhang
    Prodigy 80 points

    Hi, Hely

    I tried using sendust core, I got significant improvement in inductor performance which indicates it was core loss in inductor. 

    thank you