Optimizing Magnetic Core Gapping

for
Low-Loss Sine-wave Inductors

Kenneth Pagenkopf
Principal Engineer

January 30, 2014

OPTIMIZING CORE GAPPING

Basics
Three-Phase Reactors
Gapping Theory
Inductance Prediction
Fundamental Gap Theory
Applying the Theory
Flux Density Management
Benefits of Distributed Gapping
For Improving the Efficiency of Magnetics in
Power Converters
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BASICS

BASICS

Applications
Motor Drives
Inverters
Regenerative Systems

BASICS
PWM Waveforms

From PWM

From Drive

From Filter

Ideally, the Voltage Should Be Sinusoidal

Ideally, the Voltage Should Be Sinusoidal

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BASICS

Sine-wave Filter
Inductors
Slows Current
Changes

VL=L di/dt

Capacitors
Slows Voltage
Changes

IC=C dv/dt

Low-Pass Filter
Removes HF from
the 60Hz Signal

Ideally, the Voltage Should Be Sinusoidal

Three Phase
Reactors

THREE PHASE REACTORS

Three-Phase Sine-wave Reactor

Steel Core Construction
Wound Coils
Clamps and Brackets

THREE PHASE REACTORS

Core Gapping
Multiple segments
Inside the Coils
Evenly Spaced

THREE PHASE REACTORS

Core Construction

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Gapping Theory

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GAPPING THEORY
Single Gap Reluctance

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GAPPING THEORY
Multiple Gap Reluctance

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GAPPING THEORY
Gap Fringing
Affected by Location
Affected by Core Structure

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GAPPING THEORY
Gap Fringing
Effect of Coils
Constrains Fringing

Akin to Skin Effect, Opposing Forces

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GAPPING THEORY
lm

Gap Fringing
Refinement

lg

Gap Size Same

Changes Effective
Area (Ae)

Ag

Ae

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GAPPING THEORY
Inductance Calculation

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Inductance
Prediction

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INDUCTANCE PREDICTION

Inductance Calculation Refinement

Fringing Increases Inductance
Ae includes Steel Stacking Factor

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INDUCTANCE PREDICTION

Fringing Factor Refinement

From McLyman
(1 gap)

From Williams
(multiple gaps)

Both are Empirical

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INDUCTANCE PREDICTION

A New Fringing Formula

Ks is a Ratio of Stack to Lam
Kf is Based on a New Fundamental Gap Theory

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Fundamental
Gap Theory

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FUNDAMENTAL GAP THEORY

Upper Limits

FF Becomes Indeterminate
Can be Approximated

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FUNDAMENTAL GAP THEORY

Fundamental Gap Theory

Equivalent Distributed Gap
That Matches the Infinite Case
Also Empirical

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FUNDAMENTAL GAP THEORY

Predicted Fundamental Gaps

Coil is Approximately Centered and Matched to the Leg
Coil Size is Matched to the Window
Window is Reasonably Matched to the Lam Size

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FUNDAMENTAL GAP THEORY

Predicted Inductance from Fundamental Gap

Equivalent Distributed Gap
Matching Infinite Case
Also Empirical

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Applying the
Theory

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APPLYING THE THEORY

Gap Positions
Positions Have Fringe Constants Based on Coil Centering

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APPLYING THE THEORY

Developed Formula
Derived from Simulated and Actual Test Data

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APPLYING THE THEORY

Various Gap Configurations

Compared Simulated and Actual Test Data

Can Apply to Any Combination of Gap

Positions
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APPLYING THE THEORY

Predicted Fundamental Gaps
Predicts Well for Multiple Gaps

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APPLYING THE THEORY

Predicted Fundamental Gaps
Increasing Errors as lg Exceeds lfund

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Flux Density
Management

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FLUX DENSITY MANAGEMENT

Transformers
Faradays Law V=-d/dt and B=/Ae

Ae

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FLUX DENSITY MANAGEMENT

Inductors
Using Ohms Law: V=IR=IXL=2fLI
I

Ae

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FLUX DENSITY MANAGEMENT

Reducing Bmax
Reducing Fringing Reduces L
L Can Be Restored By More N, Which Lowers B
Can Tradeoff for More Ae

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FLUX DENSITY MANAGEMENT

Actual Redesigns
Lower Bmax for HF Core Loss in Sine-wave Reactors
Single Gap is Too Large
Distributed Gap Preserves N or Ae

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Benefits of
Distributed
Gapping

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BENEFITS OF DISTRIBUTED GAPPING

Inductance Balance Between Phases

Improves With More and Smaller Gaps to Center

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BENEFITS OF DISTRIBUTED GAPPING

Reduced Gap Losses

Pg=KiLamlg f B2

lg

Lam

Smaller lg
Smaller Pg
Smaller FF & More Turns,
Smaller B, Smaller Pg

Reduced Flux Density Significantly Reduces

Losses
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BENEFITS OF DISTRIBUTED GAPPING

Tested Actual Gap Losses

Foil More Sensitive to Edge Gaps

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BENEFITS OF DISTRIBUTED GAPPING

Match Gaps to Winding Type

More Gaps in the Right Places

Ideal Gapping for Wire

Ideal Gapping for Foil

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OPTIMIZING CORE GAPPING

Understand Gap Fringing

Know Limitations of Single Gaps
Utilize Gap Distribution
Predict Inductance
Maintain Size
Improve Imbalance
Lower Losses

and

Save Energy
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Questions?

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References:
(1) McLyman, Colonel William T. " Transformer and Inductor Design
Handbook. 3rd ed. New York: Marcel Dekker, 2004. Chapter 10. Print.
(2) Flux Fringing and Distributed Air Gap, (www.encyclopediamagnetics.com)
(3) Williams, Keith L. Practical Inductor Design. EMCW Expo Milwaukee
WI May 9, 2013

(4) Inductor and Flyback Transformer Design, Section 5. (www.ti.com)

Footnotes:
-ANSYS Maxwell 3D FEA program was used to predict
inductances and was confirmed by lab assembly and test.
-JFE Steel core materials aided in the separation of gap losses from core
losses in measurements due to their low loss.
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