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Chapter 15 Transformer Design:: N + (T) - + (T) - (T) (T)
Chapter 15 Transformer Design:: N + (T) - + (T) - (T) (T)
Chapter 15 Transformer Design:: N + (T) - + (T) - (T) (T)
Some more advanced design issues, not considered in previous chapter: n1 : n2 Inclusion of core loss + + i1(t) Selection of operating flux v2(t) v1(t) density to optimize total loss Multiple winding design: as in the coupled-inductor case, allocate the available window area among several windings A transformer design procedure How switching frequency affects transformer size
1
i2(t)
R1
R2 + vk(t) : nk Rk ik (t)
Transformer design: Basic constraints A step-by-step transformer design procedure Examples AC inductor design Summary
P fe = K fe(B) A c l m
Typical value of for ferrite materials: 2.6 or 2.7 B is the peak value of the ac component of B(t), i.e., the peak ac flux density So increasing B causes core loss to increase rapidly This is the first constraint
Flux density
Constraint #2
Flux density B(t) is related to the applied winding voltage according to Faradays Law. Denote the voltseconds applied to the primary winding during the positive portion of v1(t) as 1:
t2
v1(t) area 1
t1
t2
1 =
t1
v1(t)dt
This causes the flux to change from its negative peak to its positive peak. From Faradays law, the peak value of the ac component of flux density is
To attain a given flux density, the primary turns should be chosen according to
B =
1 2n 1A c
4
n1 =
1 2BA c
Copper loss
Constraint #3
Allocate window area between windings in optimum manner, as described in previous section Total copper loss is then equal to
2 2 1 tot
with
Pcu =
(MLT)n I WAK u
I tot =
j=1
nj n1 I j
2 I 2 1 tot Pcu = 4K u
(MLT ) WA A2 c
1 B
Ptot
P fe = K fe(B) A c l m
Optimum B B
2 I 2 1 tot Pcu = 4K u
Fundamentals of Power Electronics
(MLT ) WA A2 c
1 B
6
fe
2 I 2 1 tot Pcu = 4K u
(MLT ) WA A2 c
1 B
dP fe = K fe (B) d(B)
Aclm
(MLT) (B) 3 WA A2 c
B =
2 I 2 1 tot 2K u
(MLT ) 1 3 W A A c l m K fe
Total loss
Substitute optimum B into expressions for Pcu and Pfe. The total loss is:
+2
Ptot = A c l m K fe
2 +2
2 I 2 1 tot 4K u
(MLT ) WA A2 c
+2
2 +2
Rearrange as follows:
WA Ac
2( 1)/
2/ (MLT )l m
+2
2 +2
+2
2 I 2 K fe 1 tot 4K u Ptot
2/
+ 2 /
K gfe =
WA Ac
2( 1)/
2/ (MLT)l m
+2
2 +2
+2
K gfe
2 I 2 K fe 1 tot 4K u Ptot
2/
+ 2 /
Appendix D lists the values of Kgfe for common ferrite cores Kgfe is similar to the Kg geometrical constant used in Chapter 14: Kg is used when Bmax is specified Kgfe is used when B is to be chosen to minimize total loss
10
Procedure
1. Determine core size
2 I 2 K fe 1 tot 4K u Ptot
2/
K gfe
+ 2 /
10 8
Select a core from Appendix D that satisfies this inequality. It may be possible to reduce the core size by choosing a core material that has lower loss, i.e., lower Kfe.
12
2.
2 I 2 (MLT ) 1 tot 1 B = 10 2K u W A A 3 l m K fe c
8
At this point, one should check whether the saturation flux density is exceeded. If the core operates with a flux dc bias Bdc, then B + Bdc should be less than the saturation flux density Bsat. If the core will saturate, then there are two choices: Specify B using the Kg method of Chapter 14, or Choose a core material having greater core loss, then repeat steps 1 and 2
13
3. and 4.
Primary turns:
Evaluate turns
n1 =
1 10 4 2BA c
n2 = n1 n3 = n1
n2 n1 n3 n1
14
5. and 6.
Fraction of window area assigned to each winding:
1K uWA n1 2K uWA A w2 n2 A w1
15
n 2 A c LM = 1 lm
Peak magnetizing current:
1 i M, pk = 2L M
Predicted winding resistances:
n 1(MLT) A w1 n (MLT) R2 = 2 A w2 R1 =
: nk
Rk
16
15.4.1
Ig
4A
I
20 A
Vg
25 V
v1(t) +
Use a ferrite pot core, with Magnetics Inc. P material. Loss parameters at 200 kHz are Kfe = 24.7
Fundamentals of Power Electronics
= 2.6
17
Waveforms
v1(t) VC1 Area 1
D'Ts DTs
i1(t)
I/n
I D n
+ D' I g
=4A
i2(t)
nIg
19
= 0.0858 Tesla
This is much less than the saturation flux density of approximately 0.35 T. Values of B in the vicinity of 0.1 T are typical for ferrite designs that operate at frequencies in the vicinity of 100 kHz.
20
Evaluate turns
(62.510 6) n 1 = 10 4 2(0.0858)(0.635) = 5.74 turns
n1 n 2 = n = 1.15 turns
In practice, we might select n1 = 5 and n2 = 1
This would lead to a slightly higher flux density and slightly higher loss.
21
1 = 2 =
4A 8A
1 5
= 0.5 = 0.5
20 A 8A
(Since, in this example, the ratio of winding rms currents is equal to the turns ratio, equal areas are allocated to each winding) From wire table, Appendix D: AWG #16 AWG #9
Wire areas:
22
Secondary
1 turn #9 AWG
Some alternatives
Use foil windings Use Litz wire or parallel strands of wire
23
Bmax , Tesla
2616
Switching frequency
As switching frequency is increased from 25 kHz to 250 kHz, core size is dramatically reduced
Fundamentals of Power Electronics
24
As switching frequency is increased from 400 kHz to 1 MHz, core size increases
Chapter 15: Transformer design
15.3.2
Q1
Example 2
Multiple-Output Full-Bridge Buck Converter
D1 Q3 D3
T1 n1 : +
: n2 D5
I5V i2a(t)
100 A
+ 5V
Vg
160 V
i1(t) v1(t)
D2 D4 : n2 : n3 D7 D6
Q2
Q4
+ 15 V
i2b(t)
25
Allow transformer total power loss of Ptot = 4 W = 1.724106 (approximately 0.5% of total output power)
T1 n1 : +
: n2 D5
v1(t)
Vg
i2a(t)
Area 1 = Vg DTs 0 Vg 0
i1(t) v (t) 1
D4 : n2 : n3 D7 D6
i1(t)
n n2 I 5V + 3 I 15V n1 n1
i2b(t)
0
i3a(t)
i2a(t)
n n2 I 5V + 3 I 15V n1 n1
I5V 0.5I5V 0
D8 : n3
i2b(t)
i3a(t)
I15V 0.5I15V 0
0 DTs Ts Ts+DTs 2Ts
27
28
0
n n2 I 5V + 3 I 15V n1 n1
n2 n3 I 1 = n I 5V + n I 15V 1 1
D = 5.7 A
29
I 2 = 1 I 5V 1 + D = 66.1 A 2
I 3 = 1 I 15V 1 + D = 9.9 A 2
Fundamentals of Power Electronics
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Itot
RMS currents, summed over all windings and referred to primary
I tot =
all 5 windings
nj n2 n3 n1 I j = I 1 + 2 n1 I 2 + 2 n1 I 3
31
From Appendix D
32
Eq. (15.20):
Plug in values:
1/4.6
= 0.23 Tesla
This is less than the saturation flux density of approximately 0.35 T
33
Evaluate turns
Choose n1 according to Eq. (15.21):
n1 =
1 10 4 2BA c
4
Loss calculation
with rounded turns
With n1 = 22, the flux density will be reduced to
36
1 =
2 =
3 =
37
= Pcu/Pdc where Pcu is the total copper loss (including proximity effects) and Pdc is the copper loss predicted by the dc resistance.
Apply transformer design procedure using this effective wire resistivity, and compute proximity loss in the resulting design. Further iterations may be necessary if the specifications are not met.
Fundamentals of Power Electronics
38
t1
t2
i(t)
Design a single-winding inductor, having an air gap, accounting for core loss
(note that the previous design procedure of this chapter did not employ an air gap, and inductance was not a specification)
39
0 Acn2 L= lg
Relationship between applied volt-seconds and peak ac flux density:
B =
I 2K u
2 2
(MLT ) 1 3 W A A c l m K fe
1 +2
B =
2nA c
K gfe
2I 2K fe 2K u Ptot
2/
+ 2 /
n 2(MLT ) 2 Pcu = I K uW A
Fundamentals of Power Electronics
40