Magnetics Design

Tuesday, October 18, 2022 Dept. of Electrical & Electronics Engg., MIT - Manipal 1
Introduction
Filter Inductor Design Constrain
The Core geometrical Constant Kg
A Step-by Step design Procedure
Summary of Key Points
Buck
Boost
Buck-Boost
Flyback, Forward, Push-Pull
Cuk
Sepic
Resonant Converters (SLR, PLR)

Energy Transfer Element is Inductor/Transformer

Tuesday, October 18, 2022 Dept. of Electrical & Electronics Engg., MIT - Manipal 2
Basics
 Permeability (μ)

 Reluctance (S)

Essential Characteristics of the Magnetic Core

Low Cost

Low Losses

High Saturation Flux Density

Temp. Linearity

Tuesday, October 18, 2022 Dept. of Electrical & Electronics Engg., MIT - Manipal 3
Types of Cores

Iron Core Ferrite Core

Flux density is more (1-1.5T) Flux density is less (0.2-0.4T)
Hysteresis loss is more Hysteresis loss is more
Core conductivity is more Core conductivity is more
Eddy current loss is more Eddy current loss is less
Operating frequency range is in Higher operating frequency
Hz to few kHz.

Tuesday, October 18, 2022 Dept. of Electrical & Electronics Engg., MIT - Manipal 4
Principles of Inductor design
Number of Turns= N
Current flowing in the coil= I Amps
Mean magnetic length of core=lc
Mean length of Airgap= lg
Cross sectional area of core=Ac
Cross sectional area of air gap =Ag

lc lc
S S
o r AC o r Ac

NI   ( SC  S g ) To produce L henries of
inductance required number of
turns need to be calculated

Tuesday, October 18, 2022 Dept. of Electrical & Electronics Engg., MIT - Manipal 5
Types of Ferrite Cores

Tuesday, October 18, 2022 Dept. of Electrical & Electronics Engg., MIT - Manipal 6
Cont…

Tuesday, October 18, 2022 Dept. of Electrical & Electronics Engg., MIT - Manipal 7
Cont…
Parameters that needs to be calculated for the Inductor design
 Window factor
 Area product
 Energy that can be handled by the Inductor
 Number of turns required

Tuesday, October 18, 2022 Dept. of Electrical & Electronics Engg., MIT - Manipal 8
Example 11.1

For the air-core coil

a) Find the inductance
 Example 11.1 cont’

b) Find the inductance if a metallic core with µr = 2000 is inserted

in the coil
 In class exercise 1
Use equation for
inductance of the coils

Find the inductance of the air-core coil

L
 In class exercise 1 part2

Repeat In class exercise 1 , but with an iron core and

conditions such that µr = 2000.
Use equation
 In class exercise 1 part2

Repeat In class exercise 1 , but with an iron core and

conditions such that µr = 2000.

We found in part 1 that Lo = 1.58 µH, so

Tuesday, October 18, 2022 Dept. of Electrical & Electronics Engg., MIT - Manipal 14
Tuesday, October 18, 2022 Dept. of Electrical & Electronics Engg., MIT - Manipal 15
Tuesday, October 18, 2022 Dept. of Electrical & Electronics Engg., MIT - Manipal 16
Tuesday, October 18, 2022 Dept. of Electrical & Electronics Engg., MIT - Manipal 17
Tuesday, October 18, 2022 Dept. of Electrical & Electronics Engg., MIT - Manipal 18
Tuesday, October 18, 2022 Dept. of Electrical & Electronics Engg., MIT - Manipal 19
Tuesday, October 18, 2022 Dept. of Electrical & Electronics Engg., MIT - Manipal 20
Tuesday, October 18, 2022 Dept. of Electrical & Electronics Engg., MIT - Manipal 21
Design an inductor for a buck converter has the following specifications

Switching frequency is 40Khz iL

iS
ig iO = 5A

S + L C +
vD vO = 5V
vg RL
iD - -
D
Vg=12+10%

Tuesday, October 18, 2022 Dept. of Electrical & Electronics Engg., MIT - Manipal 22
Tuesday, October 18, 2022 Dept. of Electrical & Electronics Engg., MIT - Manipal 23
Tuesday, October 18, 2022 Dept. of Electrical & Electronics Engg., MIT - Manipal 24
Tuesday, October 18, 2022 Dept. of Electrical & Electronics Engg., MIT - Manipal 25
Tuesday, October 18, 2022 Dept. of Electrical & Electronics Engg., MIT - Manipal 26
Window factor/ Area Product
Assume the area of cross-section of the wire is ‘a’cm2.
Number of turns required= N turns
N a
kw 
AW
NI
kw 
AW  J
Im
Crest factor (kc ) 
I ( RMS )
N I m  k w A w Ac J

Tuesday, October 18, 2022 Dept. of Electrical & Electronics Engg., MIT - Manipal 27
Cont…
di d
eL N
dt dt
e  LI m  NAC Bm

Energy that can be handled by inductor is

1 2
E  LI
2
1
E  NAc Bm I m
2
Calculate Area Product (Ap)
2E
Ap  AW Ac 
K w Ac JBm

Tuesday, October 18, 2022 Dept. of Electrical & Electronics Engg., MIT - Manipal 28
No. of Turns Required
Number of turns required are,
LI m
N
Ac Bm
Gauge of wire:
A=I/J

Air gap.lg: Air gap lg

Tuesday, October 18, 2022 Dept. of Electrical & Electronics Engg., MIT - Manipal 29
Core selector chart
Core Mean Core cross- Window area Area AL
length section (Aw*100mm2) Product
(mm) (Ac*100mm2) (Ap*10^4
mm2)
EE20/10/5 38 0.31 0.478 0.149 1624
EE25/9/6 51.2 0.40 0.78 0.312 1895
EE25/13/7 52 0.55 0.87 0.478 2285
EE30/15/7 56 0.597 1.19 0.71
EE36/18/11 70.6 1.31 1.41 1.847 4200
EE42/21/9 77.6 1.07 2.56 2.739 2613
EE42/21/15 93 1.82 2.56 4.659 4778
EE42/21/20 99 2.35 2.56 6.016 6231
EE65/32/13 150 2.66 5.37 14.284 4833

Tuesday, October 18, 2022 Dept. of Electrical & Electronics Engg., MIT - Manipal 30