Lightweight, High-Efficiency, High-Dynamic-Response and Low-Ripple DC-DC Converters Based on Interleaved Magnetic Integrated Switched-Coupled Inductor for Electric Propulsion Aircraft

With the development of distributed electric propulsion aircraft, researching airborne high-efficiency, high-power-density, high-gain, high-dynamic and low-ripple, low-stress DC-DC that meets aviation standards is an urgent and profoundly challenging task (Research Background). We propose a new topology to implement related applications. The new topology consists of an interleaved switched-inductor unit for a high-gain, low-ripple, and high-dynamic response, and a switched-capacitor unit for secondary boosting and low voltage stress. This study first analyzes in depth the operating principle and electrical characteristics of the proposed topology in different modes, showing that the proposed topology can achieve an extremely high voltage gain while maintaining low voltage stress. Moreover, the proposed topology employs interleaved inverse coupled inductors to eliminate right-half-plane zero (RHPZ). We establish a universal design guideline for coupled inductors by deriving the equivalent inductance equations, and we implement an ultra-lightweight switched-coupled inductor using planar thin-film integrated magnetic technology. We conduct small-signal modeling to verify the loop characteristics and stability of the proposed converter. Finally, the correctness of the theoretical analysis and the advantages of the proposed converter were verified through a 5000 W experimental prototype and comprehensive comparative experiments.