Pexprt Transformerdesign2002

PExprt
Getting Started:
A Transformer Design Example
September 2002
Notice
The information contained in this document is subject to change without notice.
Ansoft makes no warranty of any kind with regard to this material, including, but not limited to, the
implied warranties of merchantability and fitness for a particular purpose. Ansoft shall not be liable
for errors contained herein or for incidental or consequential damages in connection with the fur-
nishing, performance, or use of this material.
This document contains proprietary information which is protected by copyright. All rights are
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Microsoft® Windows® is a registered trademark of Microsoft Corporation.

UNIX® is a registered trademark of UNIX Systems Laboratories, Inc.
Saber® is a registered trademark of Synopsis Corporation.
PSpice® is a registered trademark of Cadence Corporation.
PExprt®, PEmag®, Maxwell SPICE®, SIMPLORER®, and Maxwell 2D® are registered trade-
marks of Ansoft Corporation.
© Copyright 2002 Ansoft Corporation

Printing History
New editions of this manual include material updated since the previous edition. The manual print-
ing date, indicating the manual’s current edition, changes when a new edition is printed. Minor cor-
rections and updates incorporated at reprint do not cause the date to change.
Update packages may be issued between editions and contain additional and/or replacement pages
to be merged into the manual by the user. Pages which are rearranged because of changes on a pre-
vious page are not considered to be revised.
Edition Date Software

Revision
1 September 2002 5.0
iii
Typeface Conventions
Field Names Bold type is used for on-screen prompts, field
names, and messages.
Keyboard Entries Bold type is used for entries that must be entered as
specified.
Example: Enter 0.005 in the Nonlinear Residual
field.
Menu Commands Bold type is used to display menu commands
selected to perform a specific task. Menu levels are
separated by a forward slash.
For example, the instruction “Choose File/Open”
means to choose the Open command on the File
menu.
Variable Names Italic type is used for keyboard entries when a name
or variable must be typed in place of the words in
italics.
For example, the instruction “copy filename”
means to type the word copy, to type a space, and
then to type the name of a file, such as file1.
Emphasis and Italic type is used for emphasis and for the titles of
Titles manuals and other publications.
Keyboard Keys Bold type, in a different font, is used for labeled

keys on the computer keyboard.
For example, the instruction “Press Return” means
to press the key on the computer that is labeled
Return.
iv
Installation
Before you use PExprt, you must:
1. Set up your system’s graphical windowing system.
2. Install the Ansoft software, using the directions in the Ansoft PC Installation Guide.
If you have not yet done these steps, refer to the Ansoft installation guides and the documentation
that came with your computer system, or ask your system administrator for help.
v
Other References
For more information on PExprt commands and features, refer to the PExprt online help.
To start PExprt, you must first access the Maxwell Control Panel. For more detailed information on
the Maxwell Control Panel commands, refer to the Maxwell Control Panel’s online help system.
vi
Table of Contents
1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
General Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Sample Problem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Results to Expect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
2. Creating a PExprt Project . . . . . . . . . . . . . . . . . . . . . . . 2-1
Access the Maxwell Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Start the Project Manager . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Create a Project Directory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Create a New Project . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Enter Project Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
3. Accessing the Software . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Open the New Project and Run PExprt . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
PExprt Working Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Input/Output Data Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Elements Information Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Libraries Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Graphical Information Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Preferences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Specify Modeling Language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Specify Stock Libraries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Units of Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Contents-1
4. PExprt Libraries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Types of Libraries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Stock Libraries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
User's Stock Libraries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Design Library . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Working with Libraries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Opening Stock Libraries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Creating New Stock Libraries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Saving Stock Libraries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Closing Stock Libraries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Saving the Design Library . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Closing the Design Library . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Modifying Elements in the Libraries . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Creating New Library Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Copying Elements in the Libraries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
5. Selecting the Design Library . . . . . . . . . . . . . . . . . . . . 5-1
Design Library Role . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Selecting the Design Library . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Selecting Elements in the Design Library . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Auto-Select Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
6. Waveform Input Data . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Waveforms Tab of Input/Output Data Area . . . . . . . . . . . . . . . . . . . . . . . 6-2
Waveform Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Defining the Waveform Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Graphical Information Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
7. Design Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Design Inputs Tab of Input/Output Data Area . . . . . . . . . . . . . . . . . . . . . . 7-2
Design Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
8. Modeling Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Modeling Options Tab of Input/Output Data Area . . . . . . . . . . . . . . . . . . 8-2
Modeling Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
9. List of Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Starting the Design Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Using the List of Results Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Contents-2
10. Performance Results . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
From List of Results to Performance Results . . . . . . . . . . . . . . . . . . . . . 10-2
Exploring the Performance Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
11. Constructive Results . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
Exploring the Constructive Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2
12. Generating Analytical Models . . . . . . . . . . . . . . . . . . 12-1
Generating 1D Winding Setup Designs . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2
Defining the Model Language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6
Generating the Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-7
13. Analysis Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1
Selecting Analysis Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-2
14. Using PExprt with PEmag . . . . . . . . . . . . . . . . . . . . . 14-1
Invoking PEmag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-2
Generating a PEmag Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-5
Using PEmag Models in PExprt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-7
Summary of Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-13
Explanation of Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-13
15. Linking with SIMPLORER . . . . . . . . . . . . . . . . . . . . . . 15-1
Defining the SIMPLORER Model Language . . . . . . . . . . . . . . . . . . . . . 15-2
Generating the Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-3
Using a PExprt Model in SIMPLORER . . . . . . . . . . . . . . . . . . . . . . . . . 15-4
16. Planar Magnetic Component Designs . . . . . . . . . . . . 16-1
Setting Up the Planar Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-2
17. Toroidal Component Designs . . . . . . . . . . . . . . . . . . 17-1
Setting Up the Toroidal Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-2
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index-1
Contents-3
Contents-4
Introduction
Power Electronics Expert (PExprt) is an interactive, PC-based design tool that uses analytical
expressions to design magnetic components such as transformers and inductors. For example, you
can use PExprt to design both complex planar components and multi-winding flyback transformers.
PExprt produces an optimal magnetic component design based on the waveform or electrical
parameters you enter for the power converter and based on the cores, wires, and materials you
select from a database. You only need to enter the numerical values, and PExprt automatically com-
putes design alternatives.
Rather than resulting in a single design alternative, PExprt’s output consists of a complete series of
valid designs meeting your specified design objectives. These results can then be evaluated in terms
of several criteria, including power loss and temperature rise.
PExprt also includes PEmag, a powerful magnetic analysis module based on finite element analysis
(FEA). This module conducts a detailed analysis of geometry, frequency, and material effects not
considered by PExprt. The PEmag module also generates behavioral models for use in electrical
simulators such as SIMPLORER®, PSpice®, or Saber®.
Using PExprt, you can:
• Design inductors, multi-winding transformers, coupled inductors, and flyback type compo-
nents.
• Introduce waveform or converter Data.
• Consider boost, buck, boost-buck, forward, push-pull, half-bridge, full-bridge, and flyback
converters.
• Optimize constructive parameters, such as core size, core material, number of turns, air gap
length, wire gage, and number of parallel turns.
• Calculate performance parameters, such as winding losses, core losses, flux density, DC and
AC resistance, Irms currents, magnetizing inductance, leakage inductance, and temperature
rise.
Introduction 1-1
• Consider complex effects, such as skin and proximity effects, fringing flux near the air-gap for
energy calculations, and incremental permeability as a function of the field strength.
• Generate model netlists for Maxwell SPICE®, PSpice®, SIMPLORER®, and Saber® electrical
simulators.
• Analyze the entire power electronics application of the resulting model, using an additional
electrical simulator (PSpice®, SIMPLORER®, or Saber®).
In this guide, you will use PExprt to model a transformer for a Half-Bridge converter, an example
that introduces you to the basic functions of the PExprt software.
The goals for this chapter are to:
• Understand the general procedure for creating a transformer design in PExprt.
• Review the sample problem and the procedure you will use to generate the design and obtain
the design results.
1-2 Introduction
General Procedure
General Procedure
To design a magnetic component in PExprt, follow this general procedure:
1. Select a design library from the list of stock libraries.
2. Optionally, select cores, wires, and core materials from the design library. Only the selected
elements are considered in the design process.
3. Introduce the waveform specifications.
4. Optionally, specify design inputs, such as gap position, geometry, thermal constraints, wire
spacing, maximum flux density, and maximum number of parallel turns.
5. Optionally, select modeling inputs, such as winding losses and optimization criteria.
6. Generate a list of possible designs that meet your specifications.
7. Select a design, and explore one or more performance results, such as core losses, winding
losses, or temperature rise.
8. Select a design, and explore one or more constructive results, such as core size, core material,
wire gauge, gap length, or number of turns.
9. Use the Modeler menu to do the following:
• Obtain a SIMPLORER, PSpice, Maxwell SPICE, or Saber subcircuit model of your
selected design.
• Link with PEmag modeler in order to:
• Optimize the design by generating a new model using another winding strategy.
• Compare different winding strategies in order to reduce parasitics (leakage induc-
tance, AC resistance, and capacitances).
• Quantify the effect of manufacturing tolerances or material tolerances.
• Perform sensitivity analyses.
• Analyze the impact of your design within the behavior of the entire circuit (voltage
spikes, efficiency, and ringing).
10. Optionally, you can link with SIMPLORER to simulate the entire circuit.
Introduction 1-3
Sample Problem
Sample Problem
In this guide, you will design, model and simulate a transformer for a Half-Bridge converter, using
both wires and planar conductors.
You will use the following Half-Bridge converter specifications in your design:
• Input Voltage: 50 V
• Output Voltage: 5 V
• Switching Frequency: 200 kHz
• Output Power: 100 W
• Duty Cycle: 25%
This getting started guide takes you through the setup, design, and modeling of this magnetic com-
ponent. You will cover the following steps:
1. Design a low losses transformer from the waveform specifications.
2. Model the transformer using both an analytical-based and a FEA-based model, in order to ana-
lyze the impact of the interleaving application on the power losses.
3. Simulate the entire converter, including the FEA-based model, with SIMPLORER.
4. Design a planar version of the transformer.
5. Design a toroidal version of the transformer.
After setting up the problem and generating the solutions, you will do the following:
• Select and optimize constructive parameters, including:
• Core size
• Core material
• Number of turns
• Air gap length
• Wire gauge
• Number of parallel turns
1-4 Introduction
Sample Problem
• Calculate performance parameters, including:

• Winding losses
• Core losses
• Flux density
• DC and AC resistance
• Irms currents
• Magnetizing inductance
• Leakage inductance
• Temperature rise
• Consider complex effects, including:
• Skin and proximity effects
• Interleaving applications
• Generate model netlists for the SIMPLORER electrical simulator.
• Analyze the entire power electronics application of the resulting model, using SIMPLORER.
Introduction 1-5
Results to Expect
Results to Expect
The following eight figures show the type of results you can obtain using PExprt:
Input Data Constructive Results
Performance Results List of Results
1-6 Introduction
Results to Expect
BH Magnetic Material Curve Core Data
AC Resistance FFT of the current
Time: The total time needed to complete this getting started guide is approximately 3 hours.
Introduction 1-7
Results to Expect
1-8 Introduction
Creating a PExprt Project
This guide assumes that the following products have already been installed as described in the
Ansoft and SIMPLORER installation guides:
• PExprt, including the modeling module PEmag
• SIMPLORER
Please see the Ansoft PC Installation Guide if you need to install or set up the software.
• Create a project directory in which to save the sample problems.
• Create a new project in that directory in which to save the Half-Bridge transformer problem.
Time: This chapter should take approximately 15 minutes to work through.
Creating a PExprt Project 2-1

Access the Maxwell Control Panel
Access the Maxwell Control Panel

To access PExprt, you must first access the Maxwell Control Panel, which allows you to create and
open projects for all Ansoft products.
To start the Maxwell Control Panel:
• Double-click the Maxwell icon. The Maxwell Control Panel appears.
See the Maxwell Control Panel online documentation for detailed descriptions of other options in
the Maxwell Control Panel. If the Maxwell Control Panel does not appear, refer to the Ansoft PC
Installation Guide for possible reasons.
Next you will create a new project directory in which to store the projects for the PExprt Getting
Started guides.
2-2 Creating a PExprt Project

Start the Project Manager
Start the Project Manager

You can use the Project Manager to create, rename, or delete project files. The Project Manager
also allows you to access projects created with other Ansoft products.
To access the Project Manager:
• Click PROJECTS in the Maxwell Control Panel.
The Project Manager appears, listing the current path and any existing projects.

Create a Project Directory

The first step in using PExprt to model a magnetic component is to create a project directory and a
project in which to save all the data associated with the problem.
Project directories contain specific sets of projects created with Ansoft software, categorized in
useful ways. For example, you might want to store all projects related to a particular feature or
application in one project directory.
The Project Manager should still be on the screen. You will now add the getstPExprt directory,
which will contain the PExprt project you create using this Getting Started guide.
Note: If you have already created a project directory while working through another PExprt get-
ting started guide, skip to “Create a New Project” on page 2-6.
Warning: PExprt project names should not contain blank spaces.
To create the project directory:

1. Click Add from the Project Directories list at the bottom left of the Project Manager window.
The Add a new project directory window appears, listing available directories and subdirec-
tories.
2. Double-click on the sub-directory names until the current directory (at the top of the window)
is the one where you want to locate the project.
3. Enter getstPExprt in the Alias field. An alias is a project directory name that refers to the cur-

rent directory. You can use aliases to refer to project directories located in different computer
directories, or across network drive locations.
4. Click the Make New Directory radio button.
5. Click OK. The new project directory, getstPExprt, appears in the Project Directories list
under the current default project directory.

Create a New Project

Now that you have created the project directory, create a new project named HalfBridgeXfr.
The Project Manager should still be on the screen, and the empty getstPExprt project directory
should still be selected.
To create a new project in the getstPExprt project directory:
1. With the getstPExprt directory selected, click New from the Projects list. The Enter project
name and select project type window appears.
2. Enter HalfBridgeXfr in the Name field.

3. Select Maxwell PExprt Version 5 from the Type pull-down list. The rest of the list displays
other Ansoft products for which you have licenses.
4. Enter your name or user ID in the Created By field.
• If you are using Microsoft Windows NT, 2000, or XP, your login name is automatically
entered here.
• If you are using another version of Windows, you may enter your user name or leave the
field as is.
5. Deselect the Open project upon creation check box, allowing you to create the new project
without immediately launching the software. This allows you to enter project notes before
opening the project.
6. Click OK to create the new project.
The project name appears in the list of projects in the getstart project directory. Because you
created the project, the Status is set to Writable, indicating that you have access to the project.

Enter Project Notes

It is generally a good idea to save notes about the new project so that the next time you use PExprt
you can view information about a project without opening it.
To enter a description for this project:
1. Leave Notes selected. This radio button is selected by default, and the Model option is dis-
abled for PExprt projects, which are only analytical and do not involve a physical model.
2. Click in the Notes area (its border is highlighted).
3. Enter the following in the Notes area:
This is a design of a Half-Bridge Converter Transformer
using PExprt and the Transformer Design Example Getting
Started Guide.
4. Click Save Notes.
Note: Grayed-out text on commands or buttons means that the command or button is temporarily
unavailable. The Save Notes button is grayed out unless there are changes to be saved in the
Notes area.
You are now ready to open the new PExprt project and run PExprt.


Accessing the Software
In the last chapter, you created the getstPExprt project directory and created the HalfBridgeXfr
project within that directory. Now you will open that project in PExprt and start using the software.
• Open the project you just created and run PExprt.
• Learn about the PExprt working window.
• Specify your preferences — modeling language, stock libraries, and units.
Accessing the Software 3-1

Open the New Project and Run PExprt

The newly created HalfBridgeXfr project should still be highlighted in the Project Manager
Projects list. If it is not, click the left mouse button to select it.
To open the new project in PExprt:
1. Click Open under the Notes area. PExprt opens, and the Selection of Magnetic Component
Type window appears.
2. Click the + symbol in front of Transformer to expand the tree.
3-2 Accessing the Software

3. Select the Waveform Based transformer type.
4. Click OK. The PExprt working window appears.

PExprt Working Window

The PExprt working window is divided into four sections: the Input/Output Data area, the Ele-
ments Information area, the Libraries area, and the Graphical Information area.
Input/Output Data area
Elements
Information
area
Libraries area
Graphical Information area
Input/Output Data Area

The Input/Output Data area contains different tabs, depending on the design status. The following
three tabs are the ones that initially appear:
• Waveforms tab: Use this tab to define the waveform specifications.
• Design Inputs tab: Use this tab to define the design inputs.
• Modeling Options tab: Use this tab to define the modeling options.
Use this area to define inputs and other specifications. When you change parameters in the Input/
Output Data area, the values for related parameters in that window are automatically updated. The
graph is also automatically updated in the Graphical Information area.

Elements Information Area

The Elements Information area contains information about each element included in the libraries.
When you click an element in the library tree, its information is displayed in this area.
Libraries Area
The Libraries area contains a tree with the stock and design libraries used in PExprt. Each library
contains cores, bobbins, wires, insulators, and core materials. To view the elements included in
each library, click the + symbol to expand the tree.
Graphical Information Area
The Graphical Information area displays different type of graphical information, depending on
the design status and which tab is selected in the Input/Output Data area.

Preferences
Preferences
There are several options you can specify before working with PExprt. When you click Options/
Preferences, the Preferences window appears.
This window has two tabs:

• Modeling Language tab: Use this tab to specify the model language (Maxwell SPICE, PSpice,
Saber, or SIMPLORER) to be used to write the model netlists.
• Stock Libraries tab: Use this tab to specify the libraries that you want to be opened with any
new design.
These tabs are explained in the following sections.

Preferences
Specify Modeling Language

PExprt generates magnetic component models to be used in three different electrical simulators:
Maxwell SPICE, PSpice and Simplorer.
To specify the default language:
1. Click the Modeling Language tab in the Preferences window.
2. Click the Simplorer button to select SIMPLORER as the modeling language.

3. Click Apply or OK at the bottom of the window.
Specify Stock Libraries
PExprt package includes different libraries in order to make easier you design process. Although
you can open, close and save libraries during the magnetic component design, you can also select
which libraries you want to be loaded with any new design.
See Chapter 4, “PExprt Libraries” for a detailed description of PExprt libraries.
Note: The first time you use PExprt, all the libraries included with PExprt are loaded. If you make
any changes, they apply the next time you open a new document.

Preferences
To specify the default libraries:

1. Click the Stock Libraries tab in the Preferences window.
2. To load a new stock library:

a. Click Add New. The Browse Libraries window appears.
b. Find and select the library you want to add, and click Open. The new library appears in
the list.
3. To remove a library from the list:
a. Select a library from the Libraries to be loaded as “Stock” list.
b. Click Remove. The library is removed from the list. The next time you open a PExprt
design, the removed library does not appear in the Stock Library tree.
4. Click OK at the bottom of the window.
Note: In this example project, you do not need to add or remove any libraries in the Preferences
window.

Units of Measurement
You can also specify the unit of length you want to use in PExprt. For this example, you want to use
millimeters.
To specify millimeters as the unit of length:
1. Choose Options/Units. The Units window appears.
2. Select Millimeters, and click OK.


PExprt Libraries
PExprt works with libraries in order to select elements (for example, cores, wires, core materials)
that you want to be considered during the design process.
• Learn about the types of libraries available in PExprt.
• Work with PExprt libraries.
PExprt Libraries 4-1

Types of Libraries
Types of Libraries
PExprt libraries contain the cores, bobbins, wires, and core materials needed to design magnetic
components. Two different types of libraries are available in PExprt: stock libraries and design
libraries. They are displayed in the Libraries area, in the lower-left portion of the PExprt working
window.
Stock Libraries
User’s Stock Library

Design Libraries
Stock Libraries
These libraries are included with PExprt and are saved in the /PExprt_Install/Lib/PExprt direc-
tory, where PExprt_Install is the location where you installed PExprt. Seven libraries are provided
with the PExprt installation:
• Ferroxcube (former Philips)
• Epcos (former Siemens)
• TDK
• Magnetics
• AVX
• Micrometals
• Steward
Stock libraries are locked, and you cannot modify them. Once you drag a stock library into the
design library folder, the new copy is editable, but the original stock library remains locked.
User's Stock Libraries
You can create your own stock libraries in order to introduce elements you commonly employ in
your applications. These libraries can be composed of custom elements, as well as any of the ele-
ments contained in the stock libraries. You can name, save, modify, and lock/unlock user stock
libraries.
Design Library
A project’s design library is the only library that is considered during the design process. All or part
of the elements in this library are included during the design process.
You specify a design library for your project by dragging one from the stock library tree in the
Libraries area of the PExprt working window.
4-2 PExprt Libraries

Working with Libraries

Before designing a magnetic component, you first need to load stock libraries so that they appear in
the Libraries area of the PExprt working window.
Opening Stock Libraries
The first time you run PExprt, all libraries included with PExprt are loaded with any new project.
You can change this using the Stock Libraries feature on the Options/Preferences menu, as was
explained in “Specify Stock Libraries” on page 3-7.
To load additional stock libraries:
1. Click the Libraries/Stock Libraries/Load Stock Library menu, as shown below:
2. Use the browser to select the desired library.

3. After you load a new stock library, that library appears under the Stock Libraries tree in the
Libraries area.

Creating New Stock Libraries

To create your own stock library:
1. Click Libraries/Stock Libraries/New Stock Library. A new library named User Library
appears under the Stock Libraries tree.
Saving Stock Libraries

To save a stock library:
1. Click Libraries/Stock Libraries/Save Stock Library or Library/Stock Libraries/Save
Stock Library As. The Select Library window appears. Only user-created libraries appear in
the list of possible libraries to be saved.
2. Select the library you want to save from the list.

3. Click OK.
Closing Stock Libraries
To close any of the stock libraries:
• Click Libraries/Stock Libraries/Close Stock Library.

Saving the Design Library

To save the design library:
1. Click Libraries/Design Library/Save Design Library or Library/Design Library/Save
Design Library As. The Select Library window appears.
2. Select the library you want to save from the list, and click OK.
Closing the Design Library
To close the current design library:
• Click Libraries/Design Library/Close Design Library.
Modifying Elements in the Libraries
You can modify elements contained in any unlocked library, allowing you to create your own ele-
ments and customize your own libraries.
To edit an element, double-click it.
The following points describe the library element parameters you can modify:
1. Cores: When you double-click a core element (for example RM type), a properties window for
that element appears:
• Click the Core Properties tab of this window to modify the effective values and thermal
conductivity.

• Click the Dimensions tab to modify the dimensions of this particular core.
2. Bobbins: When you double-click a bobbin, a properties window for that element appears:
• Use this window to modify the dimensions and thermal conductivity for the selected bob-
bin.
3. Wires: When you double-click a wire (for example a SOLID one), a properties window for

that element appears:
• Use this window to modify the dimensions and thermal conductivity for the selected wire.
4. Material: When you double-click a core materials, a properties window appears for that ele-
ment:
• Click the Electrical Properties tab of this window to modify the electrical parameters.
• Click the Additional Parameters tab to introduce the losses parameters, thermal conduc-
tivity, and dependency of the permeability with the magnetic field strength, as shown

below:
• Click the Graphical Information tab to graphically represent the incremental permeabil-
ity, core losses and the B-H curve, as shown below:

Creating New Library Elements

Use the Add New command on the shortcut menu to create a new element in an unlocked library.
To create a new element:
1. Right-click the element type. For example, to create a new PQ core, right-click the PQ label. A
shortcut menu appears.
2. Select Add New from the shortcut menu.
A new PQ core, named New Core, appears at the end of the PQ cores list.
Copying Elements in the Libraries

You can drag and drop elements from any stock library to the design library.
Note: Elements are copied element by element; you cannot copy an entire type of elements. For
example, it is not possible to copy all ETD cores from one of the stock libraries by dragging
the ETD label. You must copy each individual ETD core.


Selecting the Design Library
In Chapter 3 you opened the HalfBridgeXfr project, explored the PExprt working window, and
reviewed the general procedure for creating a magnetic component design with PExprt. In Chapter
4 you learned how to work with PExprt libraries.
You are now ready to start defining the project for the Half-Bridge transformer design; the first step
is to define the design library.
• Understand the role of the design library in the design process.
• Define the design library for the Half-Bridge transformer sample project.
Selecting the Design Library 5-1

Design Library Role
Design Library Role

The PExprt design engine calculates the power losses of all possible combinations of cores, wires,
and cores materials that are selected using the specified design library. Using the design library, you
can do the following:
• Define design constrains selecting part or only one of the cores, wires, and core materials con-
tained in the design library.
• Consider multiple combinations of the various cores, wires, and core materials contained in the
design library.
The design library is the library that contains the elements considered for the final design. Any ele-
ment not included the design library is ignored during the design process.
You can select the elements you want to include in the design library or allow PExprt to automati-
cally select the elements for you, based on encoded design criteria described later. See the section
“Auto-Select Feature” on page 5-5 for more information on how PExprt selects elements for you.
Selecting the Design Library
You select the design library by dragging one of the loaded stock libraries and dropping it onto the
Design Library tree folder in the Libraries area of the PExprt working window. In this example,
you are going to use the Ferroxcube library as the design library.
To specify the design library:
• Drag the Ferroxcube library from the Stock Library tree folder, and drop it onto the Design
Library tree folder.
A copy of Ferroxcube library, named Ferroxcube_Design, appears under the Design Library tree.
Note: The stock libraries included with PExprt are locked and cannot be modified. Any library
created by the user can be modified. Once you copy a stock library, into the design library
folder, you can then modify the copied version.
5-2 Selecting the Design Library

Design Library Role
Selecting Elements in the Design Library

Once you have specified a design library, you can identify constraints for your design by selecting
particular elements to be considered in your design. If you skip this step, PExprt automatically
selects these elements for you using the Auto-Select feature.
This example guides you through selecting the wire gauge but allows PExprt to select the other ele-
ments (cores and core materials) using Auto-Select.
To select the wire gauge:
1. Click the Wires tab in the Libraries area of the PExprt working window.
2. Expand the Ferroxcube_Design library tree by clicking the + symbol in front of its name.
3. Expand the SOLID wire type by clicking on the "+" symbol in front of it.

Design Library Role
4. Right-click the AWG17, AWG19, AWG21, AWG23, and AWG25 elements to select them.
A tool icon appears next to each element that has been selected.
Note: To select all the elements contained in under a tree, right-click the type name label, and
select Select All.
You could repeat the steps above to select core shapes and core materials from the design library
but will allow PExprt to use the Auto-select feature to specify those elements.

Design Library Role
Auto-Select Feature
If you do not select elements on your own from the design library, PExprt can do so for you using
its AutoSelect feature. The Auto-Select feature is applied just before starting the design procedure,
immediately after you click Calculations/Start Design Process.
PExprt’s Auto-Select feature applies the following default selection criteria when selecting ele-
ments:
• Core Shapes:
• Inductors and Coupled Inductors: POT, RM, EE, and EP
• Transformers and Flyback: RM, EE, and ETD
• Planar components: RM, EE, and EI
• Toroidal components: Toroids
• Core Sizes:
• PExprt selects the size of the cores based on the power handled by the component.
• Wire Type:
• PExprt selects solid cylindrical wires for concentric and toroidal designs, and selects toroi-
dal designs and planar conductors for planar designs.
• Wire Area:
• PExprt selects one out of every three wires so that different diameters may be considered.
• Core Materials:
• PExprt selects a maximum of three core materials, based on the frequency and amplitude
of the first harmonic of the current waveform and its DC level.
Note: If the current design library does not contain bobbins for the selected cores, the core shapes
and sizes are selected according to the bobbin shapes and sizes of the design library.

Design Library Role

Waveform Input Data
After you have selected the design library and the elements to be considered during the design pro-
cess, you need to introduce the waveform specifications. Waveform specifications include wave-
form type and voltage shape.
The goal for this chapter is to:
• Enter waveform specifications.
Note: PExprt can use the Half-Bridge topology included in the standard topologies.
However, this guide shows how to introduce the information using the waveform-based
approach.
A second PExprt Getting Started Guide, Getting Started: An Inductor Design Example,
illustrates the converter-based approach.
Waveform Input Data 6-1

Waveforms Tab of Input/Output Data Area
Waveforms Tab of Input/Output Data Area

To enter converter specification, click the Waveforms tab in the Input/Output Data area of the
PExprt working window.
6-2 Waveform Input Data

Waveform Types
Waveform Types
For general cases, there are a variety of ways to define waveforms. By introducing the data via the
waveform, rather than using the converter topology, offers more flexibility when designing trans-
formers for non-standard topologies.
There are two types of voltage available to apply to the transformer:
• Square
• Sinusoidal
If you select Sinusoidal, the graphical information for the waveform is updated as shown below:
Voltage Current
If you select Square, two additional choices appear for the voltage shape:
• Symmetrical
• Asymmetrical

Waveform Types
A Symmetrical voltage waveform means that the absolute values of the positive and negative lev-
els of the voltage are the same. The following combinations are available when using a symmetrical
waveform, depending on the center tap selection of the windings:
Case Primary Voltage Primary Current Secondary CurrentSecondary Current
Primary and
Secondary with
NO center tap.
Example: Variation
of Half Bridge and
Full Bridge
Converters
Primary with NO
center tapped and
Secondary with
center tap.
Example: Half
Bridge and Full
Bridge Converters
Primary with
center tap and
secondary with NO
center tap.
Example: Variation
of Push-Pull
Converter
Primary and
secondary with
center tap.
Example: Push-Pull
Converter

Waveform Types
An Asymmetrical voltage waveform means that the absolute values of the positive and negative
levels of the voltage may be different, as shown below:
Voltage Current

Defining the Waveform Data

As mentioned in Chapter 1, the specifications of the Half-Bridge converter are as follows:
• Input Voltage: 50 V
• Output Voltage: 5 V
• Switching Frequency: 200 kHz
• Output Power: 100 W
• Duty Cycle 25%
Using the equations that command the Half-Bridge converter behavior, it is very simple to obtain
the waveforms applied to the transformer. These waveforms are shown below:
Primary
Winding:
Secondary
Winding:

To meet the above specifications, you need to enter the waveform parameters in PExprt on the
Waveforms tab of the Input/Output Data area.
To enter the data, do the following in the Windings Definition table of the Input/Output Data
area:
1. Enter 25 in the Vpos column for the primary winding (the first row, #1).
2. Enter 5 in the Turns ratio column for the primary winding.
3. Enter 2 in the Turns ratio column for the secondary winding (the second row, #2).
4. Enter 100 in the Power column for the secondary winding.
5. Select the CT check box for the secondary winding to set it to be center tapped.
6. Click File/Save to save the project.
The following values should now appear in the window:
Note: The non-editable values are updated every time you introduce a value in the grid positions
of the Windings Definition table.


The Graphical Information area of the PExprt working window is used to represent the wave-
forms applied to the transformer. The waveform shape and values are updated each time you intro-
duce a value in the edit boxes and refocus.
You can see primary or secondary waveforms by clicking on the grid control in the Windings Def-
inition table.
If you click on any parameter for the primary winding row (in the Input/Output Data area), PEx-
prt displays the primary winding waveforms (in the Graphical Information area).
If you click on any parameter for the secondary winding row, PExprt displays the secondary wind-
ing waveforms.

Design Inputs
After you have selected the design library and introduced the specifications for the waveform, as
described in Chapter 6, “Waveform Input Data”, you are ready to design the component and can go
on to Chapter 9, “List of Results”. However, before you do so, you may want to customize your
design by introducing several optional design inputs.
• Learn how design parameters impact the final design.
Design Inputs 7-1

Design Inputs Tab of Input/Output Data Area

To enter design inputs:
1. Click the Design Inputs tab in the Input/Output Data area of the PExprt working window.
The Design Inputs tab appears in the PExprt working window.
2. For this example, keep the default values.
7-2 Design Inputs

Design Parameters
The Design Inputs tab is shown below with the default values:
These parameters impact the final PExprt design as explained below:
Parameter Available Options Design Impact

Geometry Concentric Component The selected geometry type is applied for the
Planar Component design.
Toroidal Component
Bobbin Include If this option is not selected, PExprt presents
designs with no bobbin. By default, concentric
components include a bobbin, and planar
components do not include a bobbin. Toroidal
components never include a bobbin.
Ventilation Low This value determines the film coefficient for the
Type Normal radiation of temperature. Low means close
environment, while High means forced
High
ventilation. When you select Low, you obtain a
higher temperature rise than when you select
High for the same specifications.
Parallel Max. Parallel Turns PExprt uses this value for the maximum number
Options of parallel windings to be considered during the
design process.
Design Inputs 7-3

Turns Ratio Maximum Variation (as a If you select Exact Value, the exact turns ratio is
percentage of the input turns forced, and PExprt does not optimize the design
ratio) to find the optimal number of turns for each
Exact Value winding. Ansoft recommends selecting
Maximum Variation in order to allow PExprt
to find the design with the optimal degree of
freedom for the turns ratio.
Winding 2D Winding Setup This parameter determines the most feasible
Setup 1D "completely-full" layers winding strategy in order to create the setup you
specify (i.e., to create a 1D analytical-based
1D "Partially-Full"
model or a 2D FEA-based model).
The following types of models are available:
• 2D Winding Strategy: PExprt allows more
than one winding in the same layer. For
example, two parallel windings may be
placed in the same layer.
• 1D “completely-full” layers: PExprt fills
the layers with turns, filling the entire
window height.
• 1D “Partially-Full”: PExprt allows layers
partially filled with turns.
Winding Awire/Awinding (Wire area/ The parameter determines how to modify the
Efficiency Winding area) wire spacing. The worse the winding spacing,
Spacing the lower the number of wires that fit in the
window.
Margin % Window Height PExprt presents solutions with the specified top
Tapes % Window Width and central margin tape percentages, as shown
below:
Top Margin Tape
Central Margin
7-4 Design Inputs

Maximum Maximum Temperature Rise PExprt presents solutions with a temperature rise
Temperature below the this value.
Rise
Bmax/Bsat Bmax/Bsat This value is specified as a percentage of the
saturation flux density and is the maximum
value of flux density PExprt considers for the
calculations. (PExprt is not designed to provide
components working above saturation value of
the flux density.)
Minimum Minimum Primary Winding PExprt presents solutions with a higher
Primary Magnetizing Inductance magnetizing inductance than the one specified in
Winding this field.
Magnetizing
Inductance
Maximum Maximum Number of Layers This value is particularly useful in the design of
Number of planar components, where the cost of the
Layers components depends strongly on the number of
layers.
Design Inputs 7-5


This area of the PExprt working window is used to represent the waveform of the voltage and cur-
rent applied to the transformer under design. These waveforms are the same as the ones on the
Waveforms tab.
See “PExprt Working Window” on page 3-4 for a description of the working window.
7-6 Design Inputs

Modeling Inputs
After you have selected the design library and introduced the specifications of the waveform, as
described in Chapter 6, “Waveform Input Data”, you are ready to design the component and can go
on to Chapter 9, “List of Results”. However, before you do so, you may want to introduce several
optional modeling options, in order to improve the accuracy of the results.
• Learn how modeling options impact the final design.
Modeling Inputs 8-1

Modeling Options Tab of Input/Output Data Area

To enter modeling options:
1. Click the Modeling Options tab in the Input/Output Data area of the PExprt working win-
dow. The Modeling Options tab appears in the PExprt working window.
2. For this example, use the default values.
8-2 Modeling Inputs

Modeling Parameters
The Modeling Options tab is shown below with the default values:
These parameters impact the final PExprt design as explained below:

Parameter Available Options Design Impact
Winding Irms and DC Resistance During the design process, there are three possible
Losses Harmonics and AC ways to calculate the losses in the conductors:
Calculation Resistance (Skin) • Irms and DC Resistance: Winding losses are
Harmonics and AC calculated as:
Resistance (Dowell) P = I2rms * RDC
Number of harmonics: • Harmonics and AC Resistance (Skin):
Winding losses are calculated as:
P = I2DC * RDC + I2rms_1 * RAC_1 +
I2rms_2 * RAC_2 + I2rms_3* RAC_3 + ...
(where Irms_i is the rms value of the harmonic i,
and RAC_i is the resistance at the frequency of
If you account for the the harmonic i calculated with the effective area,
Harmonics in the losses accounting for the skin effect at each frequency).
calculation, you can specify • Harmonics and AC Resistance (Dowell):
how many harmonics you Winding losses are calculated as:
want to be considered during
P = I2DC * RDC + I2rms_1 * RAC_1 +
the design process. You can
I2rms_2 * RAC_2 + I2rms_3 * RAC_3 +
introduce this information
...
specifying the number of
harmonics or by means of (where Irms_i is the rms value of the harmonic i,
the relative influence of one and RAC_i is the resistance at the frequency of
harmonic with respect to the the harmonic i, calculated with the Dowell
previous one. equations).
Modeling Inputs 8-3

Optimize No Optimization If you select No Optimization, PExprt does not

number of Apply Optimization (for iterate to find the lower losses solution for each
turns for Mode 1 or Mode 2) combination of core/wire/material. If you select
minimum Apply Optimization, PExprt optimizes using two
losses possible approaches (Mode 1 or Mode 2). Click
More Info to learn more about the two approaches.
8-4 Modeling Inputs

List of Show all solutions PExprt calculates all solutions meeting the initial
Results Selection specifications, but you can configure which ones to
present. If you select Show all solutions, PExprt
shows all meeting specifications. If you select
Selection, only those that meet the selection criteria
are included on the List of Results tab.
To modify the default selection criteria, click the
Select Solutions button. In the window that appears,
you can specify how the results will be classified (by
loss, temperature rise, volume, height, or footprint)
and the number of solutions to be shown.
Selection of Apply Restrictions If you want to use all the elements you have selected
elements No Restriction (all possible in the design library for the design process, select No
from the configurations) Restrictions. However, if you have selected many
Design elements in the design library, and you do not know
Library how many of them make sense to be considered in
the design, select Apply Restrictions to allow
PExprt to select the appropriate elements for your
design.
You can configure how restrictive the criteria are for
the selection by clicking the Configure button. In the
window that appears, use the Design Constraints tab
to set the restriction level for the selections.
To learn more about how PExprt applies restrictions,
click the Information tab.
Modeling Inputs 8-5


This area of the PExprt working window is used to represent the waveform of the voltage and cur-
rent applied to the transformer under design. These waveforms are the same as the ones on the
Waveforms tab.
8-6 Modeling Inputs

List of Results
You are now ready to generate designs and explore the solution results.
• Generate the design alternatives.
• Classify the designs using the List of Results tab in the Input/Output Data area of the PExprt
working window.
List of Results 9-1

Starting the Design Process

Do the following to start the design process:
1. Click the Calculations/Start Design Process menu option. The Auto-Select feature is applied
for any elements you did not previously select in the design library.
2. Click Yes when you are asked if you want to auto-select core shapes and core materials. The
Designing Magnetic Component progress window appears.
3. When the design process is complete, a design report message appears, telling you how many
valid designs were obtained from the total number of analyzed designs. In this particular case,
PExprt tells you it has obtained 679 valid results out of 735 analyzed designs. Since you
selected Solution Selection on the Modeling Options tab, only the 10 best solutions, in terms
of losses, are shown.
4. Click OK to dismiss this window. The list of results appears on the List of Results tab of the
9-2 List of Results

Input/Output Data area:
List of Results 9-3

Using the List of Results Tab

The List of Results tab, in the Input/Output Data area, displays the results of the design process:
Do the following to configure the List of Results tab:

1. Click on the header of one of the columns to either:
• Classify that column in ascending or descending order.
• Select that particular column to be graphically represented in the Graphical Information
area.
Note: The columns containing alphanumerical values will not be graphically represented.
2. Double-click on any of the designs in the list. The Customize List of Results window appears.
9-4 List of Results

Using this window, you can:

• Show or hide columns
• Specify the range of values to represent elements in each column.
3. To present solutions with temperature rise below 15º, enter 15 in the Temperature field, the
Maximum column.
4. To simultaneously present solutions with a volume below 6000 mm3, enter 6000 in the Vol-
ume field., the Maximum column.
5. Click OK to apply the criteria to the List of Results tab.

The List of Results tab presents only solutions with a temperature rise below 15º and a volume
below 6000 mm3, as can be seen below.
6. Right-click on one of the designs of the List of Results tab, for example, the first one. A short-
cut menu appears.
7. Select Copy to My Results from the shortcut menu, as shown below:
A new tab, named My Results, appears in the Input/Output Data area. This tab contains any
designs you copied there, as in steps 4 and 5.
8. Click the My Results tab to check that the design specified in steps 4 and 5 is now copied in
List of Results 9-5

this new list, as shown below:
Note: When you save a project using File/Save, File/ Save As, or the toolbar button, the only
designs saved with the project are those on the My Results tab. Designs on the List of
Results tab window are not saved.
9-6 List of Results


This area of the PExprt working window is used to graphically represent the information for one of
the columns from the List of Results tab in the Input/Output Data area. Initially, the power losses
are represented for all the design solutions included on the List of Results tab.
List of Results 9-7

9-8 List of Results

Performance Results
After generating various designs for this particular example, you are now ready to explore the
results that PExprt provides for each design on the List of Results tab.
• Explore the Performance Results tab.
Performance Results 10-1

From List of Results to Performance Results

All the design alternatives on the List of Results tab meet your specifications. Now you need to
select one of them, so that you can explore its performance results.
To explore performance results for a specific design:
1. Click the List of Results tab.
2. Click on the header for the Power Losses column to classify the list by power loss.
Note: To reverse the order (ascending/descending), click a second time on the column header.
10-2 Performance Results

3. Select the lowest losses design.
4. Click the Performance Results tab.
Note: The results presented on the Performance Results tab correspond only to the design cur-
rently selected on the List of Results or My Results tabs.

Exploring the Performance Results

You are now ready to explore the performance results of the currently selected design.
This window contains the following sections:
• Input/Output Data area: This area is used to show the numerical values of the performance
results.
• Graphical Information area: This area is used to graphically represent the following parame-
ters:
• Power Losses distribution: This parameter represents the ratio between core losses and
wire losses. In this example, the core/winding losses sharing is balanced, which is a classi-
cal rule of thumb.
However, there are cases where this sharing may be different for the optimal solution.
PExprt looks for the optimal case independently of the core/winding losses sharing and
then bases the calculations on the exploration of combinations of "core/wire/core mate-
rial" in order to find the optimum solution. Therefore, the loss sharing is simply output
information, rather than a function of the optimization goal. Depending on each design
(namely on the waveforms applied to the component), the loss sharing could be more or
less balanced.
• Window Filling: This parameter represents the ratio between the total wire area in the
window and the total air area in the window.
• Window Rate: This parameter represents the ratio between the total winding area (area of

the window where the winding is placed, included the air among turns) and the area of the
window where there is not any winding.
The following performance results parameters are shown on the Performance Results tab in the
Input/Output Data area of the PExprt working window:
1. Losses:
• Core: This performance results parameter represents the losses in the core of the magnetic
component under the defined working conditions. To explore the core losses in more
detail, click on the core losses value display, which is also a button. When you click this
button, the Core Losses window appears, describing how the core losses are calculated
(using the Steinmetz equation).

• Winding: This performance results parameter represents the losses in the winding, apply-
ing the model that you selected on the Modeling Options tab. In this example, you are
considering the skin effect of each harmonic. To explore the winding losses in more detail,
click on the winding losses value. The Winding AC Information window appears, dis-
playing a plot of the winding resistance as a function of the frequency.
You can change the frequency range of the plot using the Min Freq. and Max Freq. fields.
Click the AC Losses tab to plot the contribution of each harmonic to the total winding losses.

Click the Current FFT tab to plot the Fast Fourier Transformation of the current waveform. This
information represents the harmonic content of the current waveform.
• Total: This performance results parameter represents the total of the core and winding
losses added together.
• Winding (DC): This performance results parameter represents the winding losses, consid-
ering only the DC resistance and the Irms.
2. Windings: The Windings area is used to represent the values of any winding.
• Current Density: This performance results parameter represents the current density in the
selected winding (the rms current value divided by the cross-section area of the wire). Par-
allel wires are taken into account.
• Magnetizing Inductance: This performance results parameter represents the magnetizing
inductance referred to the selected winding.

• Voltage: This performance results parameter represents the voltage "seen" from the
selected winding, considering the turns ratio of the final design.
• Losses (selected model): This performance results parameter represents the losses in the
selected winding under the defined current waveform. To learn about how this value is
calculated, click on the Losses (selected model). The Windings AC Information win-
dow appears, listing a detailed explanation about the losses calculation. This window can
also be opened by clicking on the Losses/Windings value as explained earlier.
• Losses (DC): This performance results parameter represents the DC losses in the selected
windings under the defined current waveform. To learn about how this value is calculated,
click on the Losses (DC) value. The Winding DC Information window appears, listing a
detailed explanation about the DC losses calculation.
• DC Resistance: This performance results parameter represents the DC resistance of the
winding. To explore the DC resistance in more detail, click on the DC Resistance value or

the Losses (DC) value. The Winding DC Information window appears.
• Irms: This performance results parameter represents the root medium square (rms) value
of the current waveform.
3. Window Occupancy:
• Window Filling: This performance results parameter represents the ratio between the
total wire area in the window and the total air area in the window.
• Window Rate: This performance results parameter represents the ratio between the total
winding area (area of the window where the winding is placed, including the air among
turns) and the area of the window where there is no winding.
4. Leakage Inductance:
• DC Value: This performance results parameter represents the low frequency value of the
leakage inductance.
• Switching frequency value: This performance results parameter represents the value of

the leakage inductance at the switching frequency.
Note: The leakage inductance values are only available for designs with a 1D winding strategy. If
the design presents a 2D winding strategy, this value is set to "NA" (Not Available).
5. Flux Density:
• Variation of B: This performance results parameter represents the variation of the flux
density in mT (tesla * 10-3).
• Maximum B: This performance results parameter represents the maximum value of the
flux density in mT (tesla * 10-3).
Note: PExprt is not designed to provide designs above saturation flux density. Therefore, the max-
imum B value always presents a value below the saturation B value.
6. Temperature Rise:
• Temperature Rise: This performance results parameter represents the temperature rise
(difference of temperature between the external air and the hottest point) in degrees centi-
grade.

Constructive Results
By now you have generated the designs for this particular example, and you have explored the Per-
formance Results tab in the Input/Output Data area of the PExprt working window. You are now
ready to explore the Constructive Results tab, which PExprt provides for each design on the List
of Results tab.
• Explore the Constructive Results tab.
Constructive Results 11-1

Exploring the Constructive Results

To view the constructive results:
• Click the Constructive Results tab in the Input/Output Data area of the PExprt working
window.
The following window appears, displaying the Constructive Results tab in the Input/Output
Data area and the cross-section of the current design in the Graphical Information area:
Note: The results presented on the Constructive Results tab correspond to only one design -- the
design that is currently selected on either the List of Results tab or the My Results tab.
11-2 Constructive Results

The following constructive results parameters are shown on the Constructive Results tab in the
Input/Output Data area of the PExprt working window:
1. Component:
• Core Size: This parameter represents the core size and name for the selected design.
• Bobbin: This parameter represents the bobbin size and name for the selected design.
• Core Material: This parameter represents the core material name for the selected design.
• Library: This parameter represents the name of the library that has been used as the
design library for the selected design.
2. Windings:
• Wire: This parameter represents the wire gauge (AWG) and name for the selected
winding.
• Number of Turns: This parameter represents the number of turns for the selected
winding.
• Parallel Turns: This parameter represents number of parallel turns for the selected
winding.
Constructive Results 11-3

You can explore the constructive elements by clicking on the "element value" button. For example,
if you want to explore the core properties, click on the ETD29 button for the Core Size field.
11-4 Constructive Results

Generating Analytical Models
PExprt includes an advanced modeling package that enables you to create accurate models of the
generated designs. The modeling module, called PEmag®, allows you to generate analytical-based
or finite element-based models. You can link directly between the design module (PExprt) and the
modeling module (PEmag), as described in Chapter 14, “Using PExprt with PEmag”.
However, if you want to quickly generate an analytical model of your design without opening
PEmag, you can use the modeling feature of PExprt, which uses the same modeling generation
engine as PEmag analytical model.
Since the modeling strategy applied to generate the model is based on analytical expressions, only
magnetic component designs that present a one-dimensional (1D) field distribution can be modeled
using this approach. Therefore, this feature is only enabled if the selected design presents a 1D field
distribution.
Note: Magnetic components with a single conductive sublayer in each layer can be modeled using
an analytical-based model. If the magnetic component contains more than one conductive
sublayer per layer, only FEA-based modeling can be used through PEmag. For example,
designs with several parallel strands in the same layer are considered as 2D. Designs with
primary and secondary windings at the same layer are also considered 2D.
If the modeling feature is grayed-out, then the selected design cannot be modeled using ana-
lytical expressions.
• Generate "1D Winding Setup" designs.
• Define the model language (Maxwell SPICE, PSpice, Saber, or SIMPLORER).
• Generate the analytical-based model.
Generating Analytical Models 12-1

Generating 1D Winding Setup Designs

To generate an analytical model directly from PExprt, you need to force PExprt to provide designs
presenting a 1D winding strategy.
Note: PExprt includes the modeling module (PEmag), which enables you to generate FEA-based
models valid for any winding strategy. The purpose of this section is to describe how to
obtain designs presenting 1D winding strategies.
To force PExprt to generate a 1D winding strategy design:

1. Click the Design Inputs tab in the Input/Output Data area of the PExprt working window.
2. Select 1D “completely-full” layers in the Winding Setup area.
Note: When you force PExprt to obtain a "1D Completely-full layers" design, the solutions are not
optimized for the number of turns. Since PExprt fills the layers with turns, the number of
turns is not a degree of freedom for optimization. Therefore, the resulting design may be far
from the optimal one.
Note: Usually this option is set to 2D Winding Setup to obtain any winding strategy. The reason
you are now setting this value to 1D “completely-full” layers is so that you can generate an
analytical models for any of the solutions. If the winding strategy presents a 1D field
distribution, PExprt generates analytical models very quickly. However, if the winding
strategy presents a 2D field distribution, PExprt may invoke the Maxwell 2D FEA solver in
order to generate the model. Therefore, the purpose of this option is so that you can generate
models for many solutions in a short time.
Ansoft recommends that you read the PEmag documentation to learn which effects are and
are not considered by the analytical model.
3. Click the Calculations/Start Design Process menu option. PExprt calculates the designs for
the same input specifications but fills the entire window height with turns. Once the design
procedure is finished, a dialog below appears telling you how many valid designs were
obtained. In this example, PExprt obtained 16 valid designs out of 585 combinations.
12-2 Generating Analytical Models

4. Click OK to dismiss the window. The new list of results appears on the List of Results tab.
Note: There are elements in the list of results with a "core icon" . This means that
these designs fulfill the exact turns ratio specification. The designs without this icon present
a turns ratio in the band that you specified on the Design Inputs tab.
5. Double-click on any of the designs of the List of Results tab. The Customize List of Results
window appears.
6. Enter 6000 in the Volume field to specify the maximum volume allowed.

7. Click OK to apply the criteria. The List of Results tab presents only solutions with volume
below 6000 mm3.
As explained before, these results may be far from the optimal ones because the number of
turns has not been optimized. Depending on the case, the results may be closer or further to
optimal. In this example, the results obtained forcing the layers to be filled with turns are far
from the optimal ones that were previously obtained using the 2D Winding Setup option.
For example, if you select the first design on the List of Results tab and explore the perfor-
mance results, you can see that the losses are higher than the optimal ones and that the core/
wire losses sharing is unbalanced.
However, the winding strategy does present a 1D distribution, allowing you to generate
analytical-based models. The winding setup can be seen when you click the Constructive
Results tab.
Note: Although the selected design is far from the optimum one, you will continue using this
design throughout the rest of this guide in order to illustrate how to work with the analytical
model and the benefits than can be obtained by using this model in your designs.
If you want to learn how to work with the 2D FEA-based model, see the PExprt Getting
Started Guide titled Getting Started: An Inductor Design Example.
Note: You can also obtain a “1D winding setup” design by selecting the 2D Winding Setup
option on the Design Inputs tab.
If you select the 2D Winding Setup option, PExprt optimizes the number of turns and then
place them in the window. If the resulting winding setup is 1D, you will obtain a 1D
solution with optimal number of turns.

Defining the Model Language
Defining the Model Language

Do the following to define the model language:
1. Click Options/Preferences. The Preferences window appears.
2. Click Simplorer to select it as the as modeling language.

3. Click OK to apply the selection and close the window.

Generating the Model

Do the following to generate the model:
1. Select the first design from the List of Results tab.
2. Click the Modeler/Generate Analytical Model menu option. A message appears, telling you
that the 1D model has been successfully generated.
3. Click OK to dismiss this message.
You can now use this model in SIMPLORER as any other circuit element. See Chapter 15, “Link-
ing with SIMPLORER” for additional information.
To explore the model netlist:
1. Click the Modeler/View Analytical Model Netlist/Simplorer menu option. Windows Note-
pad opens, displaying the SIMPLORER netlist description.
2. When you are finished viewing the netlist description, click File/Exit to exit Notepad.

Analysis Mode
So far you have been working with PExprt in Design Mode. An alternative way to work with PEx-
prt is called Analysis Mode. Analysis Mode works with only a single design, which you select from
the List of Results tab.
Once you have selected a design, you may want to change a particular parameter of this design and
then evaluate the impact of this change on the performance results. This can be done using Analysis
Mode. You can also use Analysis Mode to evaluate previous designs with PExprt. In other words, if
you have previously designed a magnetic component and you want to evaluate the losses, tempera-
ture rise, and other factors of this design, you can use Analysis Mode to introduce this design and
then obtain its performance results.
• Select and work with Analysis Mode.
Analysis Mode 13-1

Selecting Analysis Mode

Analysis Mode works with the design you have previously selected from the List of Results tab.
Make sure that you have selected the lower losses design from the List of Results tab before con-
tinuing with the example.
To select Analysis Mode:

1. Click Calculations/Analysis Mode. Since you previously copied a design to the My Results
tab, in “Using the List of Results Tab” on page 9-4, a message appears telling you the designs
on that tab will be deleted.
2. Click Yes to continue. The Constructive Results tab appears, showing the cross-section of the
selected design. You can edit several values on the Constructive Results tab: the number of
turns and the number of parallel turns.
Note: There is no design library when working in Analysis Mode. Therefore, the Design Library
folder in the library tree is hidden while you are working in this mode.
To modify one of the constructive results values in order to evaluate its impact on the design:
1. Change the Parallel Turns field to 2 (instead of the current value of 3 for the parallel wind-
ing).
2. Click Calculations/Analyze Component to evaluate the results. Since you previously gener-
ated an analytical model for the current project, a message appears, asking you if you want to
remove that model.
3. Click Yes to remove the previously generated model. The Performance Results tab appears,
showing the results for the modified design.
13-2 Analysis Mode

Reducing the number of parallel turns from 3 to 2 in the primary winding causes the winding
losses to increase from 8.85 W in the original design to 9.898 W in the modified design.
You can modify all of the constructive parameters while working in Analysis Mode.
Do the following to modify the remaining of the constructive parameters:
1. Click the Constructive Results tab.
2. Click Cores tab in the Libraries area.
3. Expand the Ferroxcube library.

4. Expand the ETD core type.
5. Drag the ETD34 core, and drop it on the area where the cross-section of the magnetic compo-
nent is represented (in the Graphical Information area). The new core is represented as
shown below:
6. Click the Bobbins tab in the Libraries area.

8. Expand the ETD bobbin type.
9. Drag the ETD34 bobbin, and drop it on the area where the cross-section of the magnetic com-
Analysis Mode 13-3

ponent is represented. The new cross-section is represented as shown below:
10. Click the Wires tab in the Libraries area.

12. Expand the SOLID wire type.
13. Drag the AWG20 wire, and drop it on the area where the cross-section of the magnetic compo-
nent is represented. This defines the wire for the first winding. The new cross-section is repre-
sented as shown below:
13-4 Analysis Mode

14. Select Winding 2 from the pull-down menu in the Windings area.
15. Expand the Ferroxcube library again in the Libraries area.

16. Expand the SOLID wire type again.
17. Drag the AWG25 wire, and drop it on the area where the cross-section of the magnetic compo-
nent is represented. This defines the wire for the second winding. The new cross-section is rep-
resented as shown below:
After modifying the constructive parameters, save the project and evaluate the results.
To save the project:
• Click the File/Save menu option.
To evaluate the results:
• Click the Calculations/Analyze Component menu option. The Performance Results tab
appears, showing the results for the modified design.
Note: If you save the project while working in Analysis Mode, the project is saved in this mode,
along with any design modifications you have applied to the selected design.
Analysis Mode 13-5

13-6 Analysis Mode

Using PExprt with PEmag
As already mentioned, the PExprt package includes a powerful modeling module, PEmag, which
allows you to generate models of the designs created using PExprt.
PEmag allows you to modify the winding setup of the current design in order to evaluate the impact
of different constructive parameters. Using PEmag you can:
• Optimize the design by generating a new model using another winding strategy.
• Compare different winding strategies in order to reduce parasitics (leakage inductance, AC
resistance, and capacitances).
• Quantify the effect of the manufacturing tolerances.
• Quantify the effect of the material tolerances.
• Perform sensitivity analyses.
• Analyze the impact of your design on the behavior of the entire circuit (voltage spikes, effi-
ciency, and ringing).
You can work with PEmag as an additional add-on module within PExprt or as a standalone appli-
cation.
Note: Refer to the PEmag Getting Started Guides to learn how to use PEmag in detail.

• Link PExprt with PEmag.
• Extract information from the model generated with PEmag.
Using PExprt with PEmag 14-1

Invoking PEmag
Invoking PEmag
You can only invoke PEmag after you have generated the List of Results tab and selected a design
from the list.
Since you have been using the Analysis mode, the initial input parameters may be now different.
For example, if you have modified the number of turns of one of the windings, the turns ratio
changes. Therefore, you first need to regenerate the original designs before invoking PEmag.
To regenerate the original design:
1. Click the Calculations/Design Mode menu option to return to Design mode.
2. Click the Waveforms tab.

3. In the Windings Definition table, make sure the Turns ratio values are correct (5:2). If not,
re-enter the Turns ratio values for the primary and secondary windings (5:2).
4. Click the Calculations/Start Design Process menu option to regenerate the design. The List
14-2 Using PExprt with PEmag

Invoking PEmag
of Results tab appears.
Now that you have regenerated the design, select a design from the List of Results tab and invoke
PEmag.
To invoke PEmag:
1. Select the first ETD design from the List of Results tab.
2. Click Modeler/Invoke PEmag Modeler. An information message appears telling you that
you are exporting the selected design to the PExprt Modeling Module (PEmag). Nonlinear
parameters are not exported to PEmag; therefore, if you need to generate models with nonlin-
ear cores in PEmag, you need to introduce the nonlinear core parameters before generating the
model.
3. Click OK to dismiss this window.

Invoking PEmag
Since you are working in Analysis Mode, PEmag opens the current design that you previously
modified, as shown below:

Generating a PEmag Model

If you are not a PEmag user, Ansoft recommends that you work through the PEmag Getting Started
Guides to learn more about the software.
To evaluate the impact of the interleaving application in your PExprt design, you are going to gen-
erate the analytical based (1D) model of the current design in PEmag.
Since the selected design contains three windings connected in parallel, the current flows through
those parallel windings in different proportions (not 1/3 though each one). The current distribution
through parallel windings depends on the frequency and on the winding strategy. This effect is dif-
ficult to accurately model using analytical calculations. The PExprt modeling module (PEmag) cal-
culates the real current distribution through parallel windings. PExprt does not calculate the actual
current distribution during the design stage (current sharing is assumed), but, once you select a par-
ticular design, you can invoke the modeler to obtain an accurate model and then use that model as
feedback for PExprt to recalculate the losses. These effects are illustrated in this section.
You will learn how to generate the analytical-based model (1D) for two current variations of the
same PExprt design:
• Without interleaving (initial PExprt design).
• With interleaving application among layers.
Interleaving application is based on the positioning of the secondary windings in between the pri-
mary parallel windings. Applying interleaving improves the current sharing between parallel wind-
ings, making the results close to when you assume ideal current sharing. However, if interleaving is
not applied, most of the primary current flows through the parallel winding closest to the secondary
windings, and losses will be higher than when you assume current sharing.
All of these effects can be explored and quantified using PExprt, without any manufacturing or
measuring iteration.
First, generate the analytical model of the current design, which does not present interleaving appli-
cation.
To generate the analytical-based model using PEmag:
1. From within PEmag, click Modeler/Analytical Modeler (1D)/Start 1D Model Generation.
The Select Analytical Calculations window appears.

2. Click the Model + Values button. Once the model is generated, a message window appears,
telling you that the analytical values have been successfully calculated.
4. Do not close PEmag. You will generate the interleaved model version shortly.
You have generated the model of the current design using the PEmag analytical model engine. This
model accounts for frequency effects (skin and proximity) more accurately than PExprt models do.
Note: One important effect is the parallel connections of the windings. PExprt assumes a
homogenous distribution of the current through parallel windings (current sharing). PEmag
models the effect accurately, calculating the real current distribution through the parallel
windings. The impact of this effect can be evaluated using PExprt in combination with
PEmag.
Refer to the PEmag documentation to learn more about the features of PEmag models.
In the next section, you will evaluate the impact of these additional losses due to the parallel con-
nections in your current PExprt design.

Using PEmag Models in PExprt

After you have generated the analytical-based model with PEmag, you can use this model to calcu-
late the losses in PExprt.
To use the PEmag analytical-based model for the losses calculation in PExprt:
dow.
2. Select PEmag Analytical Model from the Winding Losses Calculation section.
Note: The PEmag Analytical Model and PEmag FEA based Model options are disabled if the
PEmag model has not been previously generated.
3. Click Calculations/Analyze Component to evaluate the results. An information window

appears, telling you that the waveform may change because PExprt uses the AC resistance and
Magnetizing Inductance information from the PEmag FEA based model.
4. Click OK to dismiss this window. The Performance Results tab appears, showing the results.

If you select Harmonics and AC Resistance (Skin) on the Modeling Options tab for this
design, you obtain the losses shown below:
However, if you select PEmag Analytical Model on the Modeling Options tab for this
design, you obtain the losses shown below:
In this particular example, the impact of the parallel connections on the losses is about 22 W.
Since the PExprt package includes the PEmag modeling module, you can modify the winding strat-
egy in order to evaluate the impact on your design.
You will now minimize the effect of the parallel windings applying interleaving and quantify the
effect without any manufacturing iteration, using the modeling capability of PEmag.
To modify the winding strategy in PEmag:
1. Click on the red layer. A dashed white rectangle appears at that layer.
2. Click Layer/Copy Layer. The cursor changes shape, indicating that you are in the Copy Layer

mode.
3. Click on the first insulator layer from the left. The new copied layer appears at the right side of
the insulator layer.
Note: If you copy the layer in a wrong place, use the Layer/Remove Layer menu command to
correct the situation.
4. Click on the second insulator layer from the left. The new copied layer appears at the right side
of the insulator layer.
5. Click Layer/Remove Layer. The cursor changes shape, indicating that you are in the Remove
Layer mode.
6. Remove the four layers at the right by clicking on each of them, one by one. After removing

them, the connections should appear as shown below:
7. Click Connections/Add. The cursor changes shape, indicating that you are in the Add Con-
nection mode.
8. Create the connections by clicking on the round connectors, as shown below:

You have now created the interleaved version of the design, which appears as shown below:
You are now ready to generate the analytical model again with PEmag.
To generate the analytical model again with PEmag:
1. In PEmag, click Modeler/Analytical Modeler (1D)/Start 1D Model Generation. The Select
Analytical Calculations window appears.
2. Click the Model + Values button. Once the model is generated, a message window appears,

telling you that the analytical values have been successfully calculated.
Compare the results using this winding strategy with the ones previously obtained on page 14-7.
As shown previously, to use a PEmag analytical model for the losses calculation in PExprt, do the
following:
dow.
2. Select PEmag Analytical Model from the Winding Losses Calculation section.
3. Click Calculations/Analyze Component to evaluate the results. An information window
appears.
4. Click OK to dismiss this window. The Performance Results tab appears, showing the results.

Summary of Results
Summary of Results
The results are explained below, for the three different situations:
• PExprt skin and proximity effects without interleaving
• PEmag analytical-based model without interleaving
• PEmag analytical-based model with interleaving
PExprt Skin and Proximity Effects Without Interleaving:
PEmag Analytical-Based Without Interleaving:
PEmag Analytical-Based With Interleaving:
Explanation of Results
Because PExprt assumes current sharing during the design stage, the resistance that PExprt calcu-
lates is obtained assuming that 1/3 of the current flows through each parallel winding. However, in
reality, most of the current flows through only one parallel winding -- the one closest to the second-
ary winding. This increases the resistance and, also, therefore, the losses.
PEmag considers this real situation, allowing you to quantify it. PEmag accomplishes this by
allowing you to apply interleaving to modify the winding strategy in order to minimize the effect.

Summary of Results
The current sharing is improved by placing each parallel winding near a secondary winding. By
doing this, and using PEmag module, you can see that the current sharing is improved because the
losses are reduced to a value close to the ideal current sharing.
When parallel windings are used, you can see how important the interleaving application is. Using
PExprt in combination with PEmag, you can select the proper winding strategy for each applica-
tion. This is critical because a decision in the winding strategy determines the performance of the
designed component.

Linking with SIMPLORER
The analytical-based and FEA-models generated using PExprt and PEmag can be linked to differ-
ent electrical simulators in order to simulate the behavior of the entire circuit.
Ansoft SIMPLORER is one electrical simulator that can be used as part of an entire design pack-
age. The combination of PExprt, PEmag, and SIMPLORER provides a unique, powerful way to
design, model, and simulate electromagnetic systems.
• Use SIMPLORER to simulate the behavior of the entire circuit.
Note: Refer to the SIMPLORER User Guide to learn how to use the software in detail.
Linking with SIMPLORER 15-1

Defining the SIMPLORER Model Language
Defining the SIMPLORER Model Language

If you have not already done so in Chapter 11, “Constructive Results”, do the following to define
the model language:
1. Click Options/Preferences. The Preferences window appears.
2. Click Simplorer to select is as the modeling language.

3. Click OK to apply the selection and close the window.
15-2 Linking with SIMPLORER


To generate the model:
1. Click Modeler/Generate Analytical Model. A message appears, telling you that the 1D
model has been successfully generated.
2. Click OK to dismiss the window.
You are now ready to open SIMPLORER and use the generated model as part of your circuit.

Using a PExprt Model in SIMPLORER

To use a PExprt model in SIMPLORER:
1. Open the SIMPLORER application.
2. Click the toolbar button to start the SIMPLORER Schematic.
3. Right-click the Users tab. A shortcut menu appears.
4. Select Insert Library from the shortcut menu.
5. Use the browser to access the /PExprt_Install/Template/Simplorer/Library directory, where

PExprt_Install is the location where you installed PExprt.

6. Select the PExprt.smd library, and click Open. The PExprt library appears on the User tab.
Note: Steps 3 through 6 should only be performed once. The next time you open SIMPLORER,
the PExprt library is automatically loaded.
7. Click File/New on the SIMPLORER menu to create an empty schematic.

8. Select the User6 library from the Users in the ModelTree area.
Note: If you do not have a User6 library, you can create your own user library.
9. Right-click in the blank area below the library names. A shortcut menu appears.
10. Select Insert/Macro(s) from SML20-File from the shortcut menu.

11. Use the browser to access the directory where you saved the PExprt analytical project.
12. Select the halfbridgexfr.sml file, and click Open.
The Insert Macro window appears.
13. In the Insert Macro window, click on the buckinductor element of the tree ,
and then click OK. The new model (buckinductor) appears in the ModelTree area.
14. Drag the model from the ModelTree area, and drop it in the schematic area.
Note: You use the FEA-based model in SIMPLORER in the same way, selecting the FEA-based
model instead of the analytical one in steps 12 and 13.

Planar Magnetic Component Designs
More designs are beginning to use planar magnetic components, and PExprt has been designed to
work with planar designs using the same philosophy as wire components.
• Repeat the design of the Half-Bridge converter, this time using planar technology.
Planar Magnetic Component Designs 16-1

Setting Up the Planar Design

You first need to change back to Design Mode to proceed with the design process.
To set up the planar design:
1. Click Calculations/Design Mode. Since you previously generated the analytical model for the
current project, a message appears asking if you want to remove that model.
2. Click Yes to remove the previously generated model.
3. Click Design Inputs tab in the Input/Output Data area of the PExprt working window.
4. Select Planar Component as the Geometry.
5. To change the Spacing to reasonable values for a planar design, enter 150 µm in the Intra-
layer field and 200 µm in the Inter-layer field.
6. Increase the Max. Parallel Turns value from 3 to 10.
16-2 Planar Magnetic Component Designs

To select appropriate core shapes for a planar design:

1. Click the Cores tab in the Libraries area, and expand the Ferroxcube_Design library.
2. Right-click on the RM type, and select Unselect All from the shortcut menu. The RM label
now appears in gray, indicating there are no cores selected for that type.
3. Right-click on the EE type, and select Unselect All from the shortcut menu. The EE label now
appears in gray, indicating there are no cores selected for that type.
4. Right-click on the ETD type, and select Unselect All from the shortcut menu. The ETD label
now appears in gray, indicating there are no cores selected for that type.
5. Expand the RM core type, and right-click to select the RM10/ILP and RM12/ILP cores. (LP
stands for Low Profile.) A "tool" icon appears in front of each selected core, as shown below.

To start the design process for this planar component:

1. Click Calculations/Start Design Process. The Auto-Select feature is applied for the planar
wires parameter. A message appears, asking if you want to allow PExprt to auto-select the
wires.
2. Click Yes to have PExprt automatically select the wires. The design process begins. When the
design process has completed, a design report message appears, telling you how many valid
designs have been obtained from the total number of designs analyzed. In this particular case,
PExprt tells you it has obtained 12 valid results out of 191 analyzed designs. Since you speci-
fied Solution Selection on the Modeling Options tab, only the best 10 solutions, in terms of
losses, are shown.
3. Click OK to dismiss this window. The List of Results tab appears.

You can now explore the performance and constructive results, as explained in Chapter 10, “Perfor-
mance Results” and Chapter 11, “Constructive Results”.
For example, if you select the first design from the List of Results tab, and then click the
Constructive Results tab, you obtain the cross-section of the planar transformer, as shown below:


Toroidal Component Designs
PExprt has been designed to work with toroidal designs using the same philosophy as concentric
components.
• Repeat the design of the Half-Bridge transformer, this time using a toroidal core.
Toroidal Component Designs 17-1

Setting Up the Toroidal Design

To set up a toroidal design:
1. Click Design Inputs tab in the Input/Output Data area of the PExprt working window.
2. Select Toroidal Component as the Geometry.
3. To change the Spacing to reasonable values for a toroidal design, select Spacing, and enter 10
% in both the Intra-layer and Inter-layer fields.
To select appropriate core sizes for this particular toroidal design:

1. Click the Cores tab in the Libraries area, and expand the Ferroxcube_Design/Toroidal
library.
17-2 Toroidal Component Designs

2. Right-click to select TN14/9/5 and TN14/9/9. A "tool" icon appears in front of each selected
core, as shown below:
To start the design process for this toroidal component:

1. Click Calculations/Start Design Process. The Auto-Select feature is applied for the toroidal
cores and the wires selection. A window appears, asking if you want to auto-select the cores
and wires.
2. Click Yes to have PExprt automatically select the cores and wires. The design process begins.
When the design process has completed, a design report message appears, telling you how
many valid designs have been obtained from the total number of designs analyzed. In this par-
ticular case, PExprt tells you it has obtained 467 valid results out of 582 analyzed designs.
Since you specified Solution Selection on the Modeling Options tab, only the best 10 solu-
tions, in terms of losses, are shown.
Toroidal Component Designs 17-3

3. Click OK to dismiss this window. The List of Results tab appears.
You can now explore the performance and constructive results, as explained in Chapter 10, “Perfor-
mance Results” and Chapter 11, “Constructive Results”.
For example, if you select the first design from the List of Results tab, and then click the Con-
structive Results tab, you obtain the top view of the toroidal transformer, as shown below:
17-4 Toroidal Component Designs

Index
buttons 2-2
Numerics starting 2-2
creating
1D analytical model 12-7 project directory 2-4
projects 2-1, 2-6
A criteria for Auto-Select 5-5
alias 2-4
Analysis Mode 13-1 D
analytical-based model 15-3 defaults for Auto-Select 5-5
analytical-based modeling 12-1 defining modeling language 12-6
Ansoft SIMPLORER 15-1 Design Inputs tab 7-2, 7-3
Ansoft software, installing 1-v design library
automatically select design elements 5-5 role 5-2
Auto-Select feature 5-5 selecting 5-2
selecting elements 5-3
B Design Mode 13-1
design parameters 7-3
bobbin 7-3 design process
starting 9-2
C designing magnetic components
general procedure 1-3
classifying the list of results 10-2 designs
component 11-3 generating 9-1
constructive results parameters 11-3 directory
Constructive Results tab 11-1 alias 2-4
Control Panel project 2-4
about 2-2 dragging stock library to design library 5-2
Index-1
losses 10-5
E
electrical simulators 15-1 M
Elements Information area 3-5
margin tapes 7-4
English units 3-9
Maxwell 3D
installing 1-v
F Maxwell SPICE 3-6
metric units 3-9
FEA-based 2D model 14-5 model
flux density 10-10 generating analytical model 15-3
model language
G defining SIMPLORER 15-2
modeling
general procedure analytical 12-1
creating magnetic components in PExprt 1-3 generating a 1D analytical model 12-7
generating designs 9-1 modeling language 3-6
geometry 7-3 defining 12-6
Graphical Information area 3-5 Modeling Options tab 8-2, 8-3
grayed-out (text and buttons) 2-7 modeling parameters 8-3
models
I FEA 14-5
modes in PExprt 13-1
incremental permeability 10-10
Input/Output Data area 3-4
Constructive Results tab 11-1 N
Design Inputs tab 7-2 new project 2-6
List of Results tab 9-4
Modeling Options tab 8-2
Performance Results tab 10-1 O
Waveforms tab 6-2 objects
installing Ansoft software 1-v drawing 3-1
introduction opening projects 3-2
PExprt 1-1 optimizing the number of turns for minimum losses 8-
invoking PEmag modeler 14-3 4
L P
libraries parameters
stock 3-6 constructive results 11-3
Libraries area 3-5 performance results 10-5
linking to PEmag 14-1 PEmag 14-1
list of results settings 8-5 generating a model 14-5
List of Results tab 9-4
Index-2
invoking modeler module 14-3 selecting library elements 5-3
using PEmag models in PExprt 14-7 SIMPLORER 3-6, 12-6, 15-1
performance results parameters 10-5 using a PExprt model 15-4
Performance Results tab 10-1 solution results 9-1
permeability 10-10 solutions, generating 5-1
PExprt starting
general procedure for designing magnetic compo- Control Panel 2-2
nents 1-3 PExprt 3-2
results to expect 1-6 Post Processor 7-6, 13-6, 14-14, 16-5, 17-4
starting 3-2 Project Manager 2-3
PExprt project starting the design process 9-2
add 2-4 stock libraries 3-6
creating 2-1, 2-6
directory 2-4
new 2-6 T
notes 2-7 temperature rise 10-10
opening 3-2 toroidal component designs 17-1
PExprt working window 3-4
planar magnetic components 16-1
Post Processor U
starting 7-6, 13-6, 14-14, 16-5, 17-4 units of measurement 3-9
Power Electronics Expert (PExprt)
introduction 1-1
preferences 3-6 V
modeling language 3-6 ventilation type 7-3
stock library settings 3-6 viewing
units 3-9 results 7-6, 13-6, 14-14, 16-5, 17-4
Project Manager
starting 2-3
window 2-2 W
PSpice 3-6
Waveforms tab 6-2
winding DC losses 10-7
R winding efficiency 7-4
winding losses calculation 8-3
results winding setup 7-4
List of Results tab 9-1 window
results to expect in PExprt 1-6 Project Manager 2-2
results, viewing 7-6, 13-6, 14-14, 16-5, 17-4 window occupancy 10-9
role of design library 5-2 working window 3-4
S
selecting a design library 5-2
selecting elements from the design library 8-5
Index-3
Index-4

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PExprt

Microsoft® Windows® is a registered trademark of Microsoft Corporation.

© Copyright 2002 Ansoft Corporation

Edition Date Software

1 September 2002 5.0

Keyboard Keys Bold type, in a different font, is used for labeled

• Calculate performance parameters, including:

Input Data Constructive Results

Performance Results List of Results

BH Magnetic Material Curve Core Data

AC Resistance FFT of the current

Time: This chapter should take approximately 15 minutes to work through.

Creating a PExprt Project 2-1

Access the Maxwell Control Panel

2-2 Creating a PExprt Project

Start the Project Manager

Creating a PExprt Project 2-3

Create a Project Directory

Warning: PExprt project names should not contain blank spaces.

To create the project directory:

2-4 Creating a PExprt Project

Creating a PExprt Project 2-5

Create a New Project

2. Enter HalfBridgeXfr in the Name field.

2-6 Creating a PExprt Project

Enter Project Notes

Creating a PExprt Project 2-7

2-8 Creating a PExprt Project

Time: This chapter should take approximately 15 minutes to work through.

Accessing the Software 3-1

Open the New Project and Run PExprt

2. Click the + symbol in front of Transformer to expand the tree.

3-2 Accessing the Software

3. Select the Waveform Based transformer type.

4. Click OK. The PExprt working window appears.

Accessing the Software 3-3

PExprt Working Window

Input/Output Data area

Graphical Information area

Input/Output Data Area

3-4 Accessing the Software

Elements Information Area

Accessing the Software 3-5

This window has two tabs:

3-6 Accessing the Software

Specify Modeling Language

2. Click the Simplorer button to select SIMPLORER as the modeling language.

Accessing the Software 3-7

To specify the default libraries:

2. To load a new stock library:

3-8 Accessing the Software

2. Select Millimeters, and click OK.

Accessing the Software 3-9

3-10 Accessing the Software

Time: This chapter should take approximately 10 minutes to work through.

PExprt Libraries 4-1

User’s Stock Library

4-2 PExprt Libraries