A design methodology for optimizing the volume in single-layer inductors applied to PFC boost converters

In this paper is presented a design methodology for inductor in single-phase PFC boost converters operating in continuous conduction mode (CCM). The methodology is based on a simulation tool that performs an automatic selection of magnetic core taking into account the standard limits for conducted electromagnetic interference (EMI), single-layer winding pattern, and a limit for temperature rise on the inductor. Through a sweep simulation, the algorithm selects the switching frequency and the input current ripple that minimize the magnetic volume in Sendust, molypermalloy or high-flux powder cores. Also, an analysis of the use of single- or multilayer inductors is presented. The design methodology based on the models described in this paper is confirmed by experimental results obtained from a 650 W universal line input PFC prototype, considering a switching frequency of 70 kHz and an input current ripple of 40%.