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Power Electronics Ned Mohan Slides Ch30
Power Electronics Ned Mohan Slides Ch30
Outline
A.
Inductor/TransformerDesignRelationships
B.
MagneticCoresandMaterials
C.
PowerDissipationinCopperWindings
D.
ThermalConsiderations
E.
AnalysisofSpecificInductorDesign
F.
InductorDesignProcedures
G.
AnalysisofSpecificTransformerDesign
H.
EddyCurrents
J.
TransformerLeakageInductance
K.
TransformerDesignProcedures
CopyrightbyJohnWiley&Sons2003
Forclarifications:anoopmathew@ieee.org
Forclarifications:anoopmathew@ieee.oeg
Magnetics1
MagneticComponentDesignResponsibilityofCircuitDesigner
Ratings for inductors and transformers in power
electronic circuits vary too much for commercial
vendors to stock full range of standard parts.
Core
(double E)
Winding
Bobbin
Assembled
core and
winding
Magnetics2
ReviewofInductorFundamentals
Assumptions
No core losses or copper winding losses
Linearized B-H curve for core with
mo
lm >>g and A >>g2
Magnetic circuit approximations (fux
uniform over core cross-section, no
fringing flux)
Cross-sectional
area of core = A
i1
N1
Air gap: Hg
g
Starting equations
Hm lm + Hg g = N I (Amperes Law)
Bm A = Bg A = (Continuity of flux
assuming no leakage flux)
m Hm= Bm (linearized B-H curve) ;
Core: Hm
B
Bs
o Hg = Bg
Results
NI
Bs > Bm = Bg =
= / A
lm/ m+ g/ o
AN 2
LI = N ; L =
lm/ m+ g/ o
CopyrightbyJohnWiley&Sons2003
Forclarifications:anoopmathew@ieee.org
Forclarifications:anoopmathew@ieee.oeg
B
H
linear region
B
B
=
H
H
Magnetics3
ReviewofTransformerFundamentals
Assumptions same as for
inductor
Starting equations
H1 L m = N1I1 ; H2 L m = N2 I2
(Ampere's Law)
HmL m = (H1 - H2)L m = N1 I1 - N2 I2
mHm = Bm (linearized B-H curve)
d1
d2
v1 = N1
; v2 = N2
dt
dt
(Faraday's Law)
Net flux = 1 - 2 = mHmA
mA(N1I1-N 2I2)
=
Lm
Results assuming m , i.e. ideal core
or ideal transformer approximation.
=0 =
;
=
dt
N1
N2
N1
N2
CopyrightbyJohnWiley&Sons2003
Forclarifications:anoopmathew@ieee.org
Forclarifications:anoopmathew@ieee.oeg
Cross-sectional
area of core = A
i2
i1
+
v1
-
N1
+
v
2
-
N2
2
Magnetic fux
B
Bs
B
H
linear region
B
B
=
H
H
Magnetics4
Current/FluxDensityVersusCoreSize
Larger electrical ratings require larger current I and
larger flux density B.
Core losses (hysteresis, eddy currents) increase
as B2 (or greater)
Winding (ohmic) losses increase as I2 and are
accentuated at high frequencies (skin effect,
proximity effect)
B
Bs
Minor
hystersis
loop
H
- Bs
core
fringing
flux
Magnetics5
MagneticComponentDesignProblem
Challengeconversionofcomponentoperatingspecs
inconvertercircuitintocomponentdesignparameters.
Goalsimple,easytouseprocedurethatproduces
componentdesignspecsthatresultinanacceptable
designhavingaminimumsize,weight,andcost.
Inductorelectrical(e.g.convertercircuit)
specifications.
InductancevalueL
InductorcurrentsratedpeakcurrentI,ratedrms
currentIrms,andrateddccurrent(ifany)Idc
Operatingfrequencyf.
Allowablepowerdissipationininductoror
equivalentlymaximumsurfacetemperatureofthe
inductorTsandmaximumambienttemperatureTa.
Transformerelectrical(convertercircuit)
specifications.
RatedrmsprimaryvoltageVpri
RatedrmsprimarycurrentIpri
TurnsratioNpri/Nsec
Operatingfrequencyf
Allowablepowerdissipationintransformer or
equivalentlymaximumtemperaturesTsandTa
CopyrightbyJohnWiley&Sons2003
Forclarifications:anoopmathew@ieee.org
Designprocedureoutputs.
Coregeometryandmaterial.
Coresize(Acore,Aw)
Numberofturnsinwindings.
ConductortypeandareaAcu.
Airgapsize(ifneeded).
Threeimpedimentstoasimpledesignprocedure.
1. DependenceofJrmsandBoncoresize.
.
2. Howtochoseacorefromawiderangeof
materialsandgeometries.
3. Howtodesignlowlosswindingsathigh
operatingfrequencies.
Detailedconsiderationofcorelosses,winding
losses,highfrequencyeffects(skinandproximity
effects),heattransfermechanismsrequiredforgood
designprocedures.
Magnetics6
CoreShapesandSizes
Magneticcoresavailableinawidevarietyofsizesandshapes.
FerritecoresavailableasU,E,andIshapesaswellaspotcores
andtoroids.
Laminated(conducting)materialsavailableinE,U,andIshapes
aswellastapewoundtoroidsandCshapes.
OpengeometriessuchasEcoremakeforeasierfabricationbut
morestrayfluxandhencepotentiallymoresevereEMI
problems.
Closedgeometriessuchaspotcoresmakeformoredifficult
fabricationbutmuchlessstrayfluxandhenceEMIproblems.
Bobbinorcoilformerprovidedwithmostcores.
insulating layer
magnetic steel
lamination
Dimensionsofcoreareoptimizedbythemanufacturersothatfora
givenrating(i.e.storedmagneticenergyforaninductororVI
ratingforatransformer),thevolumeorweightofthecoreplus
windingisminimizedorthetotalcostisminimized.
Largerratingsrequirelargercoresandwindings.
Optimizationrequiresexperienceandcomputerizedoptimization
algorithm.
CopyrightbyJohnWiley&Sons2003
Forclarifications:anoopmathew@ieee.org
Magnetics7
DoubleECoreExample
d
a
2
a
2
a
1.9 a
1.4 a
hw
ha
bw
2
ba
Bobbin
Core
Characteristic
Core area Acore
Winding area A w
Relative Size
1.5 a2
1.4 a2
2.1 a4
13.5 a3
Winding volume V w
Total surface area of
assembled core and
winding
12.3a3
59.6 a2
CopyrightbyJohnWiley&Sons2003
Forclarifications:anoopmathew@ieee.org
Magnetics8
TypesofCoreMaterials
Iron-based alloys
Ferrite cores
Various compositions
Fe-Si (few percent Si)
Fe-Cr-Mn
METGLASS (Fe-B, Fe-B-Si, plus many
other compositions)
Important properties
Resistivity _ = (10 - 100)
Cu
Magnetics9
HysteresisLossinMagneticMaterials
B
Bs
Minor
hystersis
loop
Bac
t
Bac
Bdc
- Bs
Areaencompassedbyhysteresis
loopequalsworkdoneonmaterial
duringonecycleofappliedac
magneticfield.Areatimesfrequency
equalspowerdissipatedperunit
volume.
CopyrightbyJohnWiley&Sons2003
Forclarifications:anoopmathew@ieee.org
B(t)
Typicalwaveformsoffluxdensity,
B(t)versustime,inaninductor.
OnlyBaccontributestohysteresis
loss.
Magnetics10
QuantitativeDescriptionofCoreLosses
Eddy current loss plus hysteresis loss =
core loss.
d
Empirical equation - Pm,sp = k f a [Bac]
.
f = frequency of applied field. Bac =
base-to-peak value of applied ac field. k,
a, and d are constants which vary from
material to material
Pm,sp = 1.5x10 -6 f 1.3 [Bac] 2.5
mW/c m3 for 3F3 ferrite. (f in kHz and
B in mT)
2
Pm,sp = 3.2x10 -6 f 1.8 [Bac]
mW/c m3 METGLAS 2705 M (f in kHz
and B in mT)
Example: 3F3 ferrite with f = 100 kHz
and Bac = 100 mT, Pm,sp = 60
mW/c m3
CopyrightbyJohnWiley&Sons2003
Forclarifications:anoopmathew@ieee.org
Magnetics11
CoreMaterialPerformanceFactor
Voltamp(VA)ratingoftransformersproportionaltofBac
CorematerialshavedifferentallowablevaluesofBacataspecificfrequency.BaclimtedbyallowablePm,sp.
MostdesirablematerialisonewithlargestBac.
ChoosingbestmaterialaidedbydefininganempericalperformancefactorPF=fB ac.PlotsofPFversus
frequencyforaspecifiedvalueofPm,sppermitrapidselectionofbestmaterialforanapplication.
PlotofPFversusfrequencyatPm,sp=100mW/cm3forseveraldifferentferritesshownbelow.
CopyrightbyJohnWiley&Sons2003
Forclarifications:anoopmathew@ieee.org
Magnetics12
EddyCurrentLossesinMagneticCores
Eddy current
Bi(r)
Bo
B (r)
i
B (r)
i
B (t)
o
= exp({r - a}/ )
= skin depth =
= 2 f, f = frequency
= magnetic permeability ;
o for magnetic materials.
= conductivity of material.
Numerical example
= 0.05 cu ; = 10 3 o
f = 100 Hz
= 1 mm
CopyrightbyJohnWiley&Sons2003
Forclarifications:anoopmathew@ieee.org
Magnetics13
LaminatedCores
Coresmadefromconductivemagnetic
materialsmustbemadeofmanythin
laminations.Laminationthickness<skin
depth.
t
Stackingfactorkstack=t+0.05t
0.5 t
t (typically
0.3 mm)
Insulator
Magnetic steel
lamination
CopyrightbyJohnWiley&Sons2003
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Magnetics14
EddyCurrentLossesinLaminatedCores
Flux (t) intercepted by current loop
24core
Pec
w Ld 3 2 B2 1
d2 2 B2
Pec,sp =
=
V
24core
dwL
24core
dB(t)
dt
= 2wxBcos(t)
2wcore
Current loop resistance r =
; w >> d
L dx
Instantaneous power dissipated in thin loop
[v(t) ] 2
p(t) =
r
Average power Pec dissipated in lamination
w
x
z
w Ld 3 2 B2
24core
Pec
w Ld 3 2 B2 1
d2 2 B2
Pec,sp =
=
V
24core
dwL
24core
d
y
L
dx
B sin(
t)
-x
Eddy current fow path
CopyrightbyJohnWiley&Sons2003
Forclarifications:anoopmathew@ieee.org
Magnetics15
PowerDissipationinWindings
bobbin
Averagepowerperunitvolumeofcopperdissipated
incopperwinding=Pcu,sp=cu(Jrms)2where
Jrms=Irms/Acu andcu=copperresistivity.
Averagepowerdissipatedperunitvolumeof
winding=Pw,sp=kcu cu(Jrms)2;Vcu=kcu
VwwhereVcu=totalvolumeofcopperinthe
windingandVw=totalvolumeofthewinding.
NAcu
Copperfillfactorkcu= A <1
w
N=numberofturns;Acu=crosssectionalarea
ofcopperconductorfromwhichwindingismade;
Aw=bwlw=areaofwindingwindow.
kcu=0.3forLeitzwire;kcu=0.6forround
conductors;kcu0.70.8forrectangular
conductors.
CopyrightbyJohnWiley&Sons2003
Forclarifications:anoopmathew@ieee.org
Winding conductor
airgap
hw
Aw
g
>
g
2
bw
DoubleEcoreexample
kcu<1because:
Insulationonwiretoavoidshorting
outadjacentturnsinwinding.
Geometricrestrictions.(e.g.tightpacked
circlescannotcover100%ofasquare
area.)
Magnetics16
EddyCurrentsIncreaseWindingLosses
ACcurrentsinconductorsgenerateac
magneticfieldswhichinturngenerateeddy
currentsthatcauseanonuniformcurrent
densityintheconductor.Effectiveresistance
ofconductorincreasedoverdcvalue.
Pw,sp>kcucu(Jrms)2ifconductor
dimensionsgreaterthanaskindepth.
J(r)
J =exp({ra}/)
o
2
=skindepth=
=2 f,f=frequencyofaccurrent
=magneticpermeabilityofconductor;
=ofornonmagneticconductors.
=conductivityofconductormaterial.
Numericalexampleusingcopperat100 C
Frequency
Skin
Depth
50
Hz
10.6
mm
5
kHz
1.06
mm
20
kHz
0.53
mm
CopyrightbyJohnWiley&Sons2003
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500
kHz
0.106
mm
Eddy currents
H(t)
I(t)
J(t)
J(t)
I(t)
B sin( t)
+
-
+
-
B sin( t)
MnimizeeddycurrentsusingLeitzwire
bundle.Eachconductorinbundlehasa
diameterlessthanaskindepth.
Twistingofparalleledwirescauseseffectsof
interceptedfluxtobecanceledoutbetween
adjacenttwistsoftheconductors.Hencelittleif
anyeddycurrents.
Magnetics17
ProximityEffectFurtherIncreasesWindingLosses
a)
(b)
x
x
x
x
x
x
Proximityeffectlossesduetoeddy
currentgeneratedbythemagnetic
fieldexperiencedbyaparticular
conductorsectionbutgenerated
bythecurrentflowingintherestof
thewinding.
MMF
10
Designmethodsforminimizing
proximityeffectlossesdiscussed
later.
Eddy
Current
Losses
100
30
10
3
CopyrightbyJohnWiley&Sons2003
Forclarifications:anoopmathew@ieee.org
1
x
Magnetics18
MinimumWindingLoss
Pw=Pdc+Pec;Pec=eddycurrentloss.
Pw={Rdc+Rec}[Irms]2=Rac[Irms]2
Optimumconductorsize
Resistance
R dc
R
ec
Rac=FRRdc=[1+Rec/Rdc]Rdc
Minimumwindinglossatoptimumconductorsize.
Pw=1.5Pdc
Pec=0.5Pdc
d opt
d = conductor
diameter or
thickness
Highfrequenciesrequiresmallconductorsizesminimizeloss.
Pdckeptsmallbyputtingmaysmallsizeconductorsinparallelusing
Litzwireorthinbutwidefoilconductors.
CopyrightbyJohnWiley&Sons2003
Forclarifications:anoopmathew@ieee.org
Magnetics19
ThermalConsiderationsinMagneticComponents
Losses(windingandcore)raisecore
temperature.Commondesignpracticeto
limitmaximuminteriortemperatureto100125C.
Corelosses(atconstantfluxdensity)increase
withtemperatureincreasesabove100C
SaturationfluxdensityBsdecreaseswithtemp.
Increases
Nearbycomponentssuchaspowersemi
conductordevices,integratedcircuits,
capacitors
havesimilarlimits.
Temperaturelimitationsincopperwindings
Copperresistivityincreaseswithtemperature
increases.Thuslosses,atconstantcurrent
densityincreasewithtemperature.
Reliabilityofinsulatingmaterialsdegradewith
temperatureincreases.
CopyrightbyJohnWiley&Sons2003
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Surfacetemperatureofcomponentnearlyequalto
interiortemperature.Minimaltemperaturegradient
betweeninteriorandexteriorsurface.
Powerdissipateduniformlyincomponent
volume.
Largecrosssectionalareaandshortpath
lengthstosurfaceofcomponents.
Coreandwindingmaterialshavelargethermal
conductivity.
. Thermalresistance(surfacetoambient)ofmagnetic
componentdeterminesitstemperature.
TsTa
h
Psp=R (V +V );Rsa=A
sa w
c
s
h=convectiveheattransfercoefficient=
10Cm2/W
As=surfaceareaofinductor(core+winding).
Estimateusingcoredimensionsandsimple
geometricconsiderations.
Uncertainaccuracyinhandotherheattransfer
parametersdonotjustifymoreaccuratethermal
modelingofinductor.
Magnetics20
ScalingofCoreFluxDensityandWindingCurrentDensity
Powerperunitvolume,Psp,dissipatedinmagnetic
componentisPsp=k1/a;k1=constantand
Jrms=
Psp
1
kcurcu=k2 k a;k2=constant
cu
a=corescalingdimension.
TsTa
Pw,spVw+Pm,spVm= R
:
sa
Ta=ambienttemperatureandRsa=
surfacetoambientthermalresistanceofcomponent.
ForoptimaldesignPw,sp=Pc,sp=Psp:
TsTa
HencePsp=R (V +V )
sa w
c
Rsaproportionaltoa2and(Vw+Vc)
proportionaltoa3
CopyrightbyJohnWiley&Sons2003
Forclarifications:anoopmathew@ieee.org
Pm,sp=Psp=kfb[Bac]d;Hence
d P
k3
sp
Bac=
=
wherek3=constant
kfb
d
fba
PlotsofJrms,Bac,andPspversuscoresize
(scalefactora)foraspecificcorematerial,geometry,
frequency,andTsTavalueveryusefulforpicking
appropriatecoresizeandwindingconductorsize.
Magnetics21
ExampleofPowerDensityandCurrentDensityScaling
J rms
P
sp
mW/cm 3
A/mm 2
Assumptions
1. DoubleEcoremadefrom3F3ferrite
2. Ts=100CandTa=40C.
400
350
300
250
200
J rms
3. WindingmadewithLeitzwirekcu=
0.3
150
100
Psp
1
50
0.5
1.5
2.5
3.5
4.5
CopyrightbyJohnWiley&Sons2003
Forclarifications:anoopmathew@ieee.org
Magnetics22
AnalysisofaSpecificInductorDesign
Inductor specifications
Maximum current = 4 ams rms at 100 kHz
Double-E core with a = 1 cm using 3F3 ferrite.
Distributed air-gap with four gaps, two in series in each leg;
total gap length g = 3 mm.
Winding - 66 t urns of Leitz wire with A cu = 0.64 mm2
Inductor surface black with emissivity = 0.9
T a,max = 40 C
CopyrightbyJohnWiley&Sons2003
Forclarifications:anoopmathew@ieee.org
fringing
flux
g
g
d
A core
Ag
Magnetics23
AnalysisofaSpecificInductorDesign(cont.)
L =
N
= 310 H
I
60
373 4
- 313 4
(5.1)(0 .006)
100
100
1
R,conv =
(1.34)(0.006)
0.035
60
= 20.1 [C/W ]
fringing
flux
= 19.3 [C/W ]
g
g
A core
Ag
CopyrightbyJohnWiley&Sons2003
Forclarifications:anoopmathew@ieee.org
Magnetics24
StoredEnergyRelationBasisofInductorDesign
Inputspecificationsforinductordesign
InductancevalueL.
RatedpeakcurrentI
RatedrmscurrentIrms.
Rateddccurrent(ifany)Idc.
Designprocedurestartingpointstoredenergyrelation
[LI]Irms=[NIrms
kcuAw
N= A
cu
Operatingfrequencyf.
=BAcore;Irms=JrmsAcu
MaximuminductorsurfacetemperatureTs
andmaximumambienttemperatureTa.
LIIrms=kcuJrmsBAwAcore
Designconsistsofthefollowing:
Selectionofcoregeometricshapeandsize
Equationrelatesinputspecifications(lefthandside)to
neededcoreandwindingparameters(righthandside)
Corematerial
Windingconductorgeometricshapeandsize
Numberofturnsinwinding
Agooddesignprocedurewillconsistsofasystematic,
singlepassmethodofselectingkcu,Jrms,B,Aw,andAcore.
Goal:Minimizeinductorsize,weight,andcost.
CopyrightbyJohnWiley&Sons2003
Forclarifications:anoopmathew@ieee.org
Magnetics25
CoreDatabaseBasicInductorDesignTool
Interactive core database (spreadsheet-based) key to a single pass inductor design procedure.
User enters input specifications from converter design requirements. Type of conductor for windings
(round wire, Leitz wire, or rectangular wire or foil) must be made so that copper fill factor kcu is
known.
Spreadsheet calculates capability of all cores in database and displays smallest size core of each
type
that meets stored energy specification.
Also can be designed to calculate (and display as desired) design output parameters including J rms,
B,
Acu, N, and air-gap length.
Multiple iterations of core material and winding conductor choices can be quickly done to aid in
selection of most appropriate inductor design.
Information on all core types, sizes, and materials must be stored on spreadsheet. Info includes
dimensions, Aw, Acore, surface area of assembled inductor, and loss data for all materials of interest.
Pre-stored information combined with user inputs to produce performance data for each core in
spreadsheet. Sample of partial output shown below.
CoreNo. Material
3F3
AP=
R
Psp@
Jrms@
AwAcore T=60C T=60C T=60C
&Psp
9.8C/W
2.1
237
3.3/ kcu
4
3
cm
mW/cm
CopyrightbyJohnWiley&Sons2003
Forclarifications:anoopmathew@ieee.org
Bac@
T=60C
&100kHz
^
kcuJrmsB
170mT
AwAcore
.0125 kcu
Magnetics26
DetailsofInteractiveInductorCoreDatabaseCalculations
Userinputs:L,I,Irms,Idc,f,Ts,Ta,andkcu
Storedinformation(static,independentofconverterrequirements)
Coredimensions,Aw, Acore, Vc,Vw, surfacearea, meanturnlength,meanmagneticpathlength,etc.
Quantitativecorelossformulasforallmaterialsofinterestincludingapproximatetemperaturedependence.
Calculationofcorecapabilities(storedenergyvalue)
1. Computeconverterrequiredstoredenergyvalue:LIIrms.
2. ComputeallowablespecificpowerdissipationP sp=[TsTa]/{Rsa[Vc+Vw]}.Rsa=h/Asorcalculated
interactivelyusinginputtemperaturesandformulasforconvectiveandradiativeheattransferfromHeatSink
chapter.
3. ComputeallowablefluxdensityPsp=kfb[Bac]dandcurrentdensityPsp=kcucu{Jrms}2.
4. ComputecorecapabilitieskcuAw Acore B Jrms
Calculationofinductordesignparameters.
1.AreaofwindingconductorAcu=I/Jrms.
2. Calculateskindepthinwinding.IfAcu>2attheoperatingfrequency,thensingleroundconductorcannot
beusedforwinding.
ConstructwindingusingLeitzwire,thinfoils,orparalleledsmalldia.()roundwires.
CopyrightbyJohnWiley&Sons2003
Forclarifications:anoopmathew@ieee.org
Magnetics27
DetailsofInteractiveCoreDatabaseCalculations(cont.)
3. CalculatenumberturnsofNinwinding:N=kcuAw/Acu.
4. CalculateairgaplengthLg.Airgaplengthdeterminedonbasisthatwheninductorcurrent
equalspeakvalueI,fluxdensityequalspeakvalueB.
Formulasforairgaplengthdifferentfordifferentcoretypes.ExamplefordoubleEcore
giveninnextslide.
5. CalculatemaximuminductanceLmaxthatcorecansupport.Lmax=NAcoreBpeak/Ipeak.
IfLmax>requiredLvalue,reduceLmaxbyremovingwindingturns.
Saveoncoppercosts,weight,andvolume.
PwcanbekeptconstantbyincreasingPw,sp
KeepfluxdensityBpeakconstantbyadjustinggaplengthLg.
6. AlternativeLmaxreductionprocedure,increasingthevalueofLg,keepingeverythingelse
constant,isapoorapproach.Wouldnotreducecopperweightandvolumeandthusachieve
costsavings.Fullcapabilityofcorewouldnotbeutilized.
CopyrightbyJohnWiley&Sons2003
Forclarifications:anoopmathew@ieee.org
Magnetics28
SettingDoubleECoreAirgapLength
a
Bpeak A c
a+ d
-
d o N Ipeak
dN g
CopyrightbyJohnWiley&Sons2003
Forclarifications:anoopmathew@ieee.org
fringing
flux
g
g
d
A core
Ag
Magnetics29
SinglePassInductorDesignProcedure
Start
Enter design inputs
into core database
Examine database
outputs & select core
Neglect skin,
proximity effects?
No
Yes
Iterative selection of
conductor type/size.
Select wires
No
Estimate L
max.
Too large?
Yes
Finish
CopyrightbyJohnWiley&Sons2003
Forclarifications:anoopmathew@ieee.org
Magnetics30
InductorDesignExample
Assembledesigninputs
L=300microhenries
Peakcurrent=5.6A,
sinewavecurrent,Irms=4A
Frequency=100kHz
Ts=100C;Ta=40C
StoredenergyLIIrms=(3x104)(5.6)(4)
=0.00068Jm3
Corematerialandgeometricshape
Highfrequencyoperationdictatesferrite
material.3F3materialhashighest
performancefactorPFat100kHz.
DoubleEcorechosenforcoreshape.
DoubleEcorewitha=1cmmeetsrequirements.
^ A A
kcuJrmsB
w core0.0125 kcu0.0068
forkcu>0.3
Databaseoutput:R=9.8C/Wand
Psp=237mW/cm3
CopyrightbyJohnWiley&Sons2003
Forclarifications:anoopmathew@ieee.org
CorefluxdensityB=170mTfromdatabase.
NoIdc,Bpeak=170mT.
Windingparameters.
Litzwireused,sokcu=0.3.Jrms=6A/mm2
Acu=(4A)/(6A/mm2)=0.67mm2
N=(140mm2)((0.3)/(0.67mm2)=63turns.
(63)(170mT)(1.5x104m2)
Lmax=
5.6A
290microhenries
102
Lg=
(0.17)(1.5x104)
2.5x102
LmaxL sonoadjustmentofinductancevalue
isneeded.
Magnetics31
IterativeInductorDesignProcedure
Start
Assemble design inputs
Design winding (k
Compute L I I rms
No
,J, A cu
, N)
cu
Yes
Iterativedesignprocedureessentially
consistsofconstructingthecore
databaseuntilasuitablecoreisfound.
Choosecorematerialandshapeand
conductortypeasusual.
Usestoredenergyrelationtofindan
initialareaproductAwAcandthusan
initialcoresize.
UseinitialvaluesofJrms=24A/mm2
andBac=50100mT.
Useinitialcoresizeestimate(valueofain
doubleEcoreexample)tofindcorrected
valuesofJrmsandBacandthuscorrectedvalue
^ A A
ofkcuJrmsB
w core.
^ A A
ComparekcuJrmsB
w corewith
LIIrmsanditerateasneededintoproper
sizeisfound.
CopyrightbyJohnWiley&Sons2003
Forclarifications:anoopmathew@ieee.org
Magnetics32
Simple,NonoptimalInductorDesignMethod
AssembledesigninputsandcomputerequiredLIIrms
Start
Assemble design inputs
Choosecoregeometryandcorematerialbasedon
considerationsdiscussedpreviously.
Compute L I I rms
AssumeJrms=24A/mm2andBac=50100mTanduse
LIIrms=kcuJrmsBacAwAcoretofindtherequiredarea
productAwAcoreandthusthecoresize.
AssumedvaluesofJrmsandBacbasedonexperience.
Design winding (k cu,J, A cu
, N)
Completedesignofinductorasindicated.
Set airgap length g to
obtain desired inductance L
No
Select
larger
core size
Yes
Done
CopyrightbyJohnWiley&Sons2003
Forclarifications:anoopmathew@ieee.org
Checkpowerdissipationandsurfacetemperatureusing
assumedvaluesofJrmsandBac.Ifdissipationor
temperatureareexcessive,selectalargercoresizeandrepeat
designstepsuntildissipation/temperatureareacceptable.
Procedureissocalledareaproductmethod.Usefulin
situationswhereonlyoneoretwoinductorsaretobebuilt
andsize/weightconsiderationsaresecondarytorapid
constructionandtesting..
Magnetics33
AnalysisofSpecificTransformerDesign
Transformerspecifications
WoundondoubleEcorewith
a=1cmusing3F3ferrite.
Ipri=4Arms,sinusoidalwaveform;
Vpri=300Vrms.
Frequency=100kHz
TurnsratioNpri/Nsec=4and
Npri=32.
Windingwindowsplitevenlybetween
primaryandsecondaryandwound
withLitzwire.
Transformersurfaceblack(E=0.9)
andTa40C.
Find:corefluxdensity,leakageinductance,
andmaximumsurfacetemperatureTs,and
effectof25%overcurrentonTs.
CopyrightbyJohnWiley&Sons2003
Forclarifications:anoopmathew@ieee.org
Areasofprimaryandsecondaryconductors,
Acu,priandAcu,sec.
NpriAcu,pri
NsecAcu,sec
Aw,pri= k
;Aw,sec= k
cu,pri
cu,sec
NpriAcu,pri
NsecAcu,sec
Aw,pri+Aw,sec=Aw=
+
kcu
kcu
wherekcu,pri=kcu,sec=kcusinceweassumeprimaryand
secondaryarewoundwithsametypeofconductor.
Equalpowerdissipationdensityinprimaryandsecondarygives
Ipri
Acu,pri
Nsec
Isec=Acu,sec= Npri
kcuAw
UsingaboveequationsyieldsAcu,pri= 2N and
pri
kcuAw
Acu,sec= 2N
sec
(0.3)(140mm2)
Numericalvalues:Acu,pri=
=0.64mm2
(2)(32)
(0.3)(140mm2)
andAcu,sec=
=2.6mm2
(2)(8)
Magnetics34
AnalysisofSpecificTransformerDesign(cont.)
Power dissipation in winding Pw = kcu cu(J rms) 2 V w
radi us = b / 2
w
J rms = (4 A)/ (0.64 mm2 ) = (16 A)/ (2.6 mm2 ) = 6.2 A/ mm2
Pw = (0 .3)(2 .2x10 -8 ohm-m) (6 .2x10 6 A/ m2 ) 2 (1.23x10 -5 m3 )
Pw = 3.1 watts
1.9 a
1.4 a
425
= 0.140 T
(32) (1.5x10 -4 m 2 )(2 )(10 5 Hz)
Pcore = (13 .5 cm3 )(1 .5x10 -6 )(100 kHz) 1.3 (140 mT) 2.5 = 1.9 W
o(Npri) 2 b w lw
Leakage inductance Lleak =
3 hw
lw = 8 a = 8 cm
(4 x10-7 )(32 ) 2 (0.7)(10 -2 )(8 x10 -2 )
Lleak =
(3) (2x10 -2 )
CopyrightbyJohnWiley&Sons2003
Forclarifications:anoopmathew@ieee.org
12 microhenries
b w = 0.7a
l w = (2)(1.4a) + (2)(1.9a) + 2 (0.35bw ) = 8 a
Magnetics35
SectioningofTransformerWindingstoReduceWindingLosses
x
x
x
x
x
x
x
x
Primary
Reducewindinglossesbyreducingmagnetic
field(orequiventlythemmf)seenby
conductorsinwinding.Notpossibleinan
inductor.
Secondary
MMF
N pri I pri = N sec I sec
P
2
bw
MMF
MMF
N pri
I pri
2
Simpletwosectiontransformerwinding
situation.
0
I pri
2
CopyrightbyJohnWiley&Sons2003
Forclarifications:anoopmathew@ieee.org
N pri
I pri
4
Divisionintomultiple
sectionsreducesMMFand
henceeddycurrentlosses.
x
N pri
x
N pri
I pri
4
Magnetics36
OptimizationofSolidConductorWindings
500
m = 20
m = 18
m = 16
100
Fl h
m = 14
m = 12
m = 10
m=9
m=8
m=7
m=6
m=5
10
m=4
hw
m=3
h
m=2
1
0.6
0.1
b
bo
Locus of
minimum total loss
= 1.5 dc loss
dc loss
hw
bo
m=1
1
h/
CopyrightbyJohnWiley&Sons2003
Forclarifications:anoopmathew@ieee.org
10
do
hw
N
hw
do
Magnetics37
TransformerLeakageInductance
Linear variation of mmf in winding window indicates
spatial variation of magnetic fux in the window and thus
incomplete fux linkage of primary and secondary windings.
Hwindow = Hleak =
Hleak =
x
x
h
x
x
x
x
x
x
x
x
x
o(Hleak) 2dV
2
Vw
Volume element dV = hw lw(x)dx ; lw(x) equals the
x = current
into page
= current
out of page
x
bw
CopyrightbyJohnWiley&Sons2003
Forclarifications:anoopmathew@ieee.org
Secondary
MMF
2 NpriI pri
(1 - x/ bw) ; bw/ 2 < x < bw
hw
Lleak( Ipri) 2
Primary
2 NpriI prix
hwb w
core independent of x.
bw/ 2
Lleak( Ipri) 2
2 NpriI prix
1
o[
= (2)
] 2 hw lwdx
2
2
h
b
w w
0
o( Npri) 2 lwb w
Lleak =
3 p2 hw
If winding is split into p+1 sections, with p > 1,
leakage inductance is greatly reduced.
Magnetics38
VoltAmp(Power)RatingBasisofTransformerDesign
Inputdesignspecifications
DesignproceedurestartingpointtransformerVAratingS
RatedrmsprimaryvoltageVpri
S=VpriIpri+VsecIsec=2VpriIpri
RatedrmsprimarycurrentIpri
NpriAcoreBac
d
Vpri=Npri dt =
;Ipri=JrmsAcu,pri
2
TurnsratioNpri/Nsec
Operatingfrequencyf
MaximumtemperaturesTsandTa
Designconsistsofthefollowing:
Selectionofcoregeometricshapeandsize
Corematerial
NpriAcoreBac
S=2VpriIpri=2
JrmsAcu,pri
2
kcuAw
Acu,pri= 2N
pri
NpriAcoreBac
kcuAw
S=2VpriIpri=2
Jrms 2N
2
pri
S=VpriIpri=4.4kcufAcoreAwJrmsBac
Windingconductorgeometricshapeandsize
Numberofturnsinprimaryandsecondary
windings.
Equationrelatesinputspecifications(lefthandside)tocore
andwindingparameters(righthandside).
Desireddesignprocedurewillconsistofasystematic,
singlepassmethodofselectingkcu,Acore,Aw,Jrms,andBac.
CopyrightbyJohnWiley&Sons2003
Forclarifications:anoopmathew@ieee.org
Magnetics39
CoreDatabaseBasicTransformerDesignTool
Interactive core database (spreadsheet-based) key to a single pass tramsformer design procedure.
User enters input specifications from converter design requirements. Type of conductor for windings
(round wire, Leitz wire, or rectangular wire or foil) must be made so that copper fill factor kcu is
known.
Spreadsheet calculates capability of all cores in database and displays smallest size core of each
type
that meets V- I specification.
Also can be designed to calculate (and display as desired) design output parameters including J rms,
B,
Acu,pri, Acu,sec, Npri, Nsec, and leakage inductance..
Multiple iterations of core material and winding conductor choices can be quickly done to aid in
selection of most appropriate tranformer design.
Information on all core types, sizes, and materials must be stored on spreadsheet. Info includes
dimensions, Aw, Acore, surface area of assembled transformer , and loss data for all materials of interest.
Pre-stored information combined with user inputs to produce performance data for each core in
spreadsheet. Sample of partial output shown below.
Core
No.
Material
3F3
AP=
AwAc
2.1
4
cm
R
T=60C
9.8C/W
Psp@
Ts=100C
Jrms@
Ts=100C
237
3
mW/cm
CopyrightbyJohnWiley&Sons2003
Forclarifications:anoopmathew@ieee.org
^ AP
2.22kcufJrmsB
(f=100kHz)
&100kHz
(3.3/
)
&Psp
^
B
rated@
Ts=100C
kcu
170mT
kcuRdc
Rac
Rdc
Rac
A/mm2
2.6x103
[VA]
Magnetics40
DetailsofInteractiveTransformerCoreDatabaseCalculations
Userinputs:Vpri,Ipri,turnsratioNdc/Nsec,f,Ts,Ta,andkcu
Storedinformation(static,independentofconverterrequirements)
Coredimensions,Aw, Acore, Vc,Vw, surfacearea, meanturnlength,meanmagneticpathlength,etc.
Quantitativecorelossformulasforallmaterialsofinterestincludingapproximatetemperaturedependence.
Calculationofcorecapabilities
1. Computeconverterrequiredstoredenergyvalue:S=2V priIpri
2. ComputeallowablespecificpowerdissipationP sp=[TsTa]/{Rsa[Vc+Vw]}.Rsa=h/Asorcalculated
interactivelyusinginputtemperaturesandformulasforconvectiveandradiativeheattransferfromHeatSink
chapter.
3. ComputeallowablefluxdensityPsp=kfb[Bac]dandcurrentdensityPsp=kcucu{Jrms}2.
4. Computecorecapabilities4.4fkcuAw Acore Bac Jrms
Calculationtransformerparameters.
1. CalculatenumberofprimaryturnsNpri=Vpri/{2fAcpreBac}andsecondaryturnsNsec=Vsec/{2fAcpreBac}
2. CalculatewindingconductorareasassuminglowfrequenciesoruseofLeitzwire
Acu,pri=[kcuAw]/[2Npri]andAcu,sec=[kcuAw]/[2Nsec]
CopyrightbyJohnWiley&Sons2003
Forclarifications:anoopmathew@ieee.org
Magnetics41
DetailsofInteractiveTransformerCoreDatabaseCalculations(cont.)
3.Calculatewindingareasassumingeddycurrent/proximityeffectisimportant
Onlysolidconductors,roundwiresorrectangularwires(foils),used.J rms=[{PspRdc}/{Rackcurcu}]1/2
Conductordimensionsmustsimultaneouslysatisfyarearequirementsandrequirementsofnormalized
powerdissipationversusnormalizedconductordimensions.
Mayrequirechangeinchoiceofconductorshape.Mostlikelywillrequirechoiceoffoils(rectangular
shapes).
Severaliterationsmaybeneededtofindpropercombinationsofdimensions,numberofturnsperlayer,
andnumberoflayersandsections.
Bestillustratedbyaspecificdesignexample.
4. EstimateleakageinductanceLleak={o{Npri}2lwbw}/{3p2hw}
5. EstimateSmax=4.4kcufAcoreAwJrmsBac
6. IfSmax>S=2VpriIprireduceSmaxandsaveoncoppercost,weight,andvolume.
IfNpriwAcBac>Vpri,reduceSmaxbyreducingNpriandNsec.
IfJrmsAcu,pri>Irms,reduceAcu,priandAcu,sec.
IfS>Smaxbyonlyamoderateamount(1020%)andsmallerthanS maxofnextcoresize,increaseSmaxof
presentcoresize.
IncreaseIrms(andthuswindingpowerdissipation)asneeded.TemperatureTswillincreaseamodest
amount
abovedesignlimit,butmaybepreferabletogoingtolargercoresize.
CopyrightbyJohnWiley&Sons2003
Forclarifications:anoopmathew@ieee.org
Magnetics42
SinglePassTransformerDesignProcedure
Start
Enter design inputs
into core database
Examine database
outputs & select core
Neglect skin,
proximity effects?
No
Yes
Iterative selection of
conductor type/size.
Select w ires
No
Estimate S max
.
Too large?
Yes
Remove turns
Finish
CopyrightbyJohnWiley&Sons2003
Forclarifications:anoopmathew@ieee.org
Magnetics43
TransformerDesignExample
Designinputs
Vpri=300Vrms;Irms=4Arms
Turnsration=4
Operatingfrequencyf=100kHz
Ts=100CandTa=40C
VIratingS=(300Vrms)(4Arms)
=1200watts
Corematerial,shape,andsize.
Use3F3ferritebecauseithaslargest
performancefactorat100kHz.
UsedoubleEcore.Relativelyeasyto
fabricatewinding.
Rdc
Corevoltamprating=2,600 kcu
Rac
Usesolidrectangularconductorfor
windingsbecauseofhighfrequency.
Thuskcu=0.6andRac/Rdc=1.5.
0.6
Corevoltampcapability=2,600 1.5
=1644watts.>1200watttransformerrating.
Sizeisadequate.
CopyrightbyJohnWiley&Sons2003
Forclarifications:anoopmathew@ieee.org
Usingcoredatabase,R=9.8C/W
andPsp=240mW/cm3.
Fluxdensityandnumberofprimary
andsecondaryturns.
Fromcoredatabase,Bac=170mT.
300 2
Npri=
(1.5x104m2)(2) (105Hz)(0.17T)
=26.524. Roundeddownto24toincrease
flexibilityindesigningsectionalized
transformerwinding.
24
Nsec= 6 =6.
3.3
FromcoredatabaseJrms=
(0.6)(1.5)
=3.5A/mm2.
4Arms
Acu,pri=
=1.15mm2
2
3.5Arms/mm
Acu,sec=(4)(1.15mm2)=4.6mm2
Magnetics44
TransformerDesignExample(cont.)
Primaryandsecondaryconductorareas
proximityeffect/eddycurrentsincluded.
Assumerectangular(foil)conductorswith
kcu=0.6andlayerfactorFl=0.9.
Iteratetofindcompatiblefoilthicknesses
andnumberofwinding sections.
1stiterationassumeasingleprimarysection
andasingle secondarysectionandeachsection
havingsingleturnperlayer.Primaryhas24
layersandsecondaryhas6layers.
Acu,pri
Primarylayerheighthpri= F h
l w
1.15mm2
=(0.9)(20mm)=0.064mm
Normalizedprimaryconductorheight
Flhpri
0.9(0.064mm)
=
=
d
(0.24mm) =0.25;
=0.24mmincopperat100kHzand100C.
Optimumnormalizedprimaryconductorheight
=0.3soprimarywindingdesignissatisfactory.
CopyrightbyJohnWiley&Sons2003
Forclarifications:anoopmathew@ieee.org
Acu,sec
Secondarylayerheighthsec= F h
l w
4.6mm2
=(0.9)(20mm) 0.26mm.
Normalizedsecondaryconductorheight
Flhsec
0.9(0.26mm)
=
=
d
(0.24mm) =1
Howeverasixlayersectionhasanoptimum
=0.6.Atwolayersectionhasanoptimum
=1.2nditerationneeded.
2nditerationsectionalizethewindings.
Useasecondaryof3sections,eachhavingtwo
layers,ofheighthsec=0.26mm.
Secondarymusthavesingleturnperlayer.
Twoturnsperlayerwouldrequirehsec=0.52mm
andthus=2.Examinationofnormalizedpower
dissipationcurvesshowsnooptimum=2.
Magnetics45
TransformerDesignExample(cont.)
P
6
S
3
P
3
S
3
Threesecondarysectionsrequiresfourprimarysections.
Twoouterprimarysectionswouldhave24/6=4
turnseachandtheinnertwosectionswouldhave
24/3=8turnseach.
Needtodeterminenumberofturnsperlayerand
hencenumberoflayerspersection.
Turns/
layer
hpri
No.of
Layers
1
2
4
0.064mm
0.128mm
0.26mm
8
4
2
0.25
0.5
1
Optimum
0.45
0.6
1
Usefourturnsperlayer.Twointeriorprimary
sectionshavetwolayersandoptimumvalueof
Twooutersectionshaveonelayereachandnot
optimum,butonlyresultsinslightincreaseinloss
abovetheminimum.
CopyrightbyJohnWiley&Sons2003
Forclarifications:anoopmathew@ieee.org
P
3
S
3
P
6
LeakageinductanceLleak
(4 x109)(24)2(8)(0.7)(1)
=
=0.2H
(3)(6)2(2)
Sectionalizingincreasescapacitance
betweenwindingsandthuslowersthe
transformerselfresonantfrequency.
Smax=1644watts
RatedvalueofS=1200wattsonly
marginallysmallerthanSmax.Littleto
begainedinreducingSmaxtoSunlessa
largenumberoftransformerofthisdesign
aretobefabricated.
Magnetics46
IterativeTransformerDesignProcedure
Start
Assemble design inputs
Compute 2 V I
pri pri
Yes
Iterativedesignprocedureessentially
consistsofconstructingthecore
databaseuntilasuitablecoreisfound.
Choosecorematerialandshapeand
conductortypeasusual.
UseVIratingtofindaninitialarea
productAwAcandthusaninitialcoresize.
UseinitialvaluesofJrms=24A/mm2
andBac=50100mT.
Useinitialcoresizeestimate(valueofain
doubleEcoreexample)tofindcorrected
valuesofJrmsandBacandthuscorrected
^ A A
valueof4.4fkcuJrmsB
w core.
^ A A
Compare4.4fkcuJrmsB
w corewith
2VpriIprianditerateasneededintoproper
sizeisfound.
End
CopyrightbyJohnWiley&Sons2003
Forclarifications:anoopmathew@ieee.org
Magnetics47
Simple,NonoptimalTransformerDesignMethod
Assembledesigninputsandcomputerequired2VpriIpri
Start
Assemble design inputs
Choosecoregeometryandcorematerialbasedon
considerationsdiscussedpreviously.
AssumeJrms=24A/mm2andBac=50100mTanduse
2VpriIpri=4.4fkcuJrmsBacAwAcoretofindtherequiredarea
productAwAcoreandthusthecoresize.
AssumedvaluesofJrmsandBacbasedonexperience.
,
,N
Design winding (A
cu,pri pri
A cu,sec , N sec )
No
Completedesignoftransformerasindicated.
Select
larger
core size
Yes
Done
CopyrightbyJohnWiley&Sons2003
Forclarifications:anoopmathew@ieee.org
Checkpowerdissipationandsurfacetemperatureusing
assumedvaluesofJrmsandBac.Ifdissipationor
temperatureareexcessive,selectalargercoresizeandrepeat
designstepsuntildissipation/temperatureareacceptable.
Procedureissocalledareaproductmethod.Usefulin
situationswhereonlyoneoretwotransformersaretobebuilt
andsize/weightconsiderationsaresecondarytorapid
constructionandtesting..
Magnetics48