Design of INDUCTOR

Electrical Department
IIT Dharwad
I.Venkata Raghavendra
September 21, 2019

1. Selection of core material and its size.

Get the Area product(Ap )of the Core to be selected. It is the product of
Core area and Window area.
2.E
Ap =
kc .kw .Bm .J
where,
• E = Energy to be stored in the Inductor.
1 2
E= .L.Im
2
• kc = Crest factor of Current flowing in the Inductor. usually taken
as kc = 1.

• kw = Window factor of the Core. 0.6 for inductor EE core.

• Bm = Maximum Flux Density of the core selected.
S.no Core type Bsat Bm
1 Ferrite 0.3T 0.25T
2 CRGO steel 1.2T-14T 1.1T
3 CRNGO steel 1T-1.2T 1T
4 Powdered Iron 1.5T 1.4T
5 Amorphous Glass 1.6T 1.4T

• J = Current density of the copper wire. J = 3A/mm2

Now select the Core so that Ap value is greater than the calculated value.
2. Identify the Number of Turns Required.
Check the Core Datasheet for permeance value given as AL factor in
nH/turn2 . if Obtained ”N” number of turns required can be Obtained by
r
L
N= turns
AL

1
 (OR)
The number of turns required can also be Obtained by

ψ L.Im
N= = .
φ Bm .Ac
3. Selection of Gauge wire to wound on Bobbin .
The area of cross section of copper wire to be selected depends on the
current that we pass in it and is obtained by
Irms
am = mm2
J
Here J = 3A/mm2 for copper.
d= diameter of the wire thickness. d in mm can be obtained by using
2
am = π.d
4

Figure 1: gauge wire measurments

4. Identify the amount of airgap to be placed between cores

The air gap length to be inserted between the cores is done by using paper
and the airgap to be placed is
µ0 .N 2 .Ac
lg =
L
5. Check whether the assumptions can be reasonable neglected.
• Ensure that the L value is made independent of core length
lm
 lg
µm
• Ensure that the fringing effect can be neglected
p
lg  Ac
• Ensure that the window space of core is sufficient for winding the
required number of turns
kw .Aw  am .N

2
1 Cores available in LAB
S.no Ferrite EE core type Ac mm2 Aw mm2 Ap = Aw .Ac mm4
1 EE 16/8/5 20.1 mm2 37.62mm2 756 mm4
2 EE 20/10/6 32.1 mm2 57.4 mm2 1842 mm4
3 EE 25/13/7 52.5 mm2 87 mm2 4567 mm4
4 EE 30/15/7 60 mm2 119 mm2 7158 mm4
5 EE 42/21/7 178 mm2 256 mm2 45568 mm4
6 EE 42/21/20 234 mm2 256 mm2 59904 mm4

2 Gauge wires available in LAB

Gauge number diameter am Im
2
18 1.22 mm 1.169 mm 3.5A
20 0.91 mm 0.65 mm2 2A
21 0.813 mm 0.52 mm2 1.55A
24 0.56 mm 0.246 mm2 0.74A
29 0.35 mm 0.1 mm2 0.3A

3 Items used to design Inductor

The items that are used to Design an inductor are
• Ferrite core
• Gauge wire

• Gauge meter
• Mica sheet
• Bobbin

4 Inductance measurement circuit

The Measurement of inductance was done using the above circuit and the wave-
forms of Drain source current (blue) and voltage across the drain source (yellow
) are as shown in the Diagram.

3
(a) Wire Gauge. (b) bobbin.

(c) EE cores. (d) gaugewire.

Figure 2: Items used in the Design

4
 Figure 3: Inductance measurement circuit

Figure 4: Source drain Current and Voltages