Design of Zero-Ripple-Current Coupled Inductors with PWM signals in Continuous Conduction Mode

Coupled inductors are widely used in multiple outputs and interleaved dc–dc converters. Also filters often use coupled inductors as their inductive part. A generalized design procedure is proposed in this article focused on current ripple minimization and applicable to coupled inductors exposed to pulsewidth modulation signals and in continuous conduction mode. The design provides a very large inductance for all windings but one. Compared to other designs, it adapts to the existing magnetic properties of the magnetic device changing only the inductance ratio, simplifying the design and manufacturing process. It is based on the equivalent inductance value and its divergences. The only assumption applied is that the coupling coefficient among all windings is the same, which is an acceptable approximation in many magnetic core architectures. The theoretical results are experimentally verified. Not only almost zero ripple current is achieved, but also mass and volume is reduced compared to noncoupled inductors. This is an additional advantage of coupled inductors in mass and volume critical applications such as aerospace.