Magnetic Integration Applied to an Isolated Single-Stage AC-DC Converter

This work proposes a novel magnetic integration approach applied to a four-leg interleaved single-phase ac-dc converter topology, aimed at minimizing component count and increasing power density. The proposed design integrates an input filter inductor, two autotransformers, and two high-frequency transformers into a single magnetic structure. Using an equivalent electrical circuit model, a consistent methodology and an iterative optimized design process are derived. The magnetic arrangement and design methodology are experimentally validated using a 6.6 kW prototype. A comparative analysis with multi-component structures across various designsis presented based on a Pareto front, demonstrating that the proposed magnetic integration solution achieves lower magnetic losses and a reduced volume. Within a switching frequency range of 50 kHz to 200 kHz, reductions of up to 33.16% in losses and 55.89% in the magnetic volume are achieved.