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To the Sun !

For the Energy!


And Dream with You !

Totem_Pole PFC Coil Design


Totem_Pole PFC
 Totem_Pole PFC Coil Design 을 위한 사전 지식
 전류의 기울기는 전압과 인덕턴스에 의해 결정된다 . 그리고 인덕턴스는 흐르는 전류에 따라 달라진다 .
 스위칭 주파수와 전류의 기울기를 감안하여 전류가 포화하지 않도록 적절한 인덕턴스 값을 선정해야 한다 .

𝑑𝑖 𝑉 𝑑𝑖
𝑉 =𝐿 =
V= 작다 & L= 일정 𝑑𝑡 𝐿 𝑑𝑡
V= 일정 & L= 크다 𝑑𝑖
𝑑𝑡

V= 크다 & L= 일정
V= 일정 & L= 작다
𝑑𝑖
𝑑𝑡

 인덕턴스 값이 결정되면 ~ 이를 구현할 수 있는 적절한 페라이트 코어를 선정하고 ~ AL Value 를 활용하여


적절한 권선수를 결정한다 .
 권선수가 결정되면 Max 전류를 감안하여 권선경을 정한다 . 선정된 페라이트 코의 형상과 보빈이 있을 경우
권선이 충분히 감길 수 있는 공간이 확보될 수 있도록 코어의 형상과 보빈을 결정한다 .
 이 모든 것이 선정되면 구동에 따른 권선 Loss 와 Core Loss 를 산출한다 .

2
Totem_Pole PFC
 Totem_Pole PFC Current Wave

𝑉 𝑑𝑖
=
𝐿 𝑑𝑡

전압의 변화에 따라 전류의 기울기도 달라진다 ~!

3
Totem_Pole PFC
 Totem_Pole PFC Coil Design 예

https://gansystems.com/wp-content/uploads/2018/01/GS665BTP-REF-rev170905.pdf

4
Totem_Pole PFC
 Totem_Pole PFC Spike Reduction

THD = 8.1% THD = 3.7%

※IEEE 519 저압 기준 ( 교류 600V 이하 ) 전압 왜형률 (THD) 은 5% 미만

https://www.ti.com/lit/an/slyt650/slyt650.pdf?ts=1679135242874&ref_url=https%253A%252F%252Fwww.google.com%252F

5
Totem_Pole PFC
 Totem_Pole PFC Spike Reduction
Scenario 1 그림 5 에서 볼 수 있듯이 AC 제로 크로싱에서 작동 모드가 음의 주기에서 양의 주기로 변경되면 스위치 Q3 의
As shown in Figure 5, when the operation mode 듀티비가 거의 100% 에서 0 으로 급격히 변경됩니다 . 스위치 Q4 의 듀티비는 0 에서 거의 100% 로 급격히 변합니다 .
Q1 바디 다이오드의 느린 역회복과 Q2 의 큰 COSS 로 인해 Q2 의 VDS 전압은 여전히 ​VOUT(400V) 과 같습니다 . Q4
changes from negative cycle to positive cycle at the 가 켜지면 이 고전압이 인덕터에 인가되기 때문에 양의 전류 스파이크가 생성됩니다 . 이 시나리오는 Reference 3 에서
분석되었으며 이 문제를 해결하기 위해 Q4 소프트스타트 방법이 제안되었습니다 .
AC zerocrossing, the duty ratio of switch Q3
changes abruptly from almost 100% to zero. The
duty ratio of switch Q4 changes abruptly from zero
to almost 100%. Because of the slow reverse re-
covery of the Q1 body diode and the large COSS of
Q2, the VDS voltage of Q2 still equals VOUT (400
V). Since this high voltage is applied to the induc-
tor when Q4 turns on, a positive current spike is Negative Cycle End
generated. This scenario is analyzed in Reference 3
and a Q4 softstart method is proposed to solve this
issue.

Scenario 2
However, even with soft turn on of Q4, there are Positive Cycle Start
still excessive current spikes. This is because VAC
is very low right after zero-crossing and is therefore
insufficient for the inductor current to build up. On COSS

the other hand, when Q3 turns on with 1 – D, even


though its duty is not high, the voltage applied to
the inductor is high (400-V VOUT). The resulting 그러나 Q4 를 Soft_Start 턴온하더라도 여전히 과도한 전류 스파이크가 있습니다 . 제로 크로싱 직후 VAC 가 매우 낮아
high reverse current through the inductor causes a 인덕터 전류가 축적되기에 충분하지 않기 때문입니다 . 반면 Q3 이 1-D 로 턴온되면 듀티가 높지 않더라도 인덕터에
인가되는 전압은 높다 (400-V VOUT). 결과적으로 인덕터를 통과하는 높은 역전류로 인해 음의 전류 스파이크가
negative current spike. 발생합니다 .

https://www.ti.com/lit/an/slyt650/slyt650.pdf?ts=1679135242874&ref_url=https%253A%252F%252Fwww.google.com%252F

6
Totem_Pole PFC
 Totem_Pole PFC Spike Reduction
Scenario 3 Q2 를 켜는 타이밍도 중요합니다 . Q4 소프트 스타트 전에 Q2 가 켜지고 Q1 의 바디 다이오드가 충분히 빨리 복구되지
Timing for Q2 turn on is also critical. A short- 않으면 단락이 발생할 수 있습니다 . (Q4 Off 후 Free Wheeling 될 때 Q2 가 켜지면 Arm_Short 발생  Q2 가 너무
빨리 On 되도 문제 ~!)
through can occur if Q2 turns on before Q4 soft
start and if the body diode of Q1 does not recover
quickly enough.

Scenario 4
If Q2 turns on too late, a negative current spike can
be generated (Figure 6). The high VBUS voltage
generates a reverse inductor current when Q3 is on
while Q2 is off. This reverse current first turns off Negative Cycle End
the Q2 body diode, then starts to charge COSS of
Q2 and the VDS of Q2 builds up to a high voltage.
Then, when Q4 turns on, the high voltage (VDS +
VIN) that is applied to the inductor results in high
rising current in the inductor. Therefore, the induc-
tor’s rising and falling currents are both large mag- Positive Cycle Start
nitude, which achieves a balance that maintains the
average current at a small positive value. Now, if
Q2 suddenly turns on at t1, VDS of Q2 will be COSS

clamped to zero. When Q4 turns on, only VIN is


applied to the inductor. Since VIN is very small,
which is insufficient for the inductor to build up Q2 가 너무 늦게 켜지면 음의 전류 스파이크가 생성될 수 있습니다 . 높은 VBUS 전압은 Q3 이 켜져 있고 Q2 가 꺼져
current high enough, the inductor’s rising current 있을 때 역방향 인덕터 전류를 생성합니다 . 이 역전류는 먼저 Q2 바디 다이오드를 끈 다음 Q2 의 COSS 를 충전하기
시작하고 Q2 의 VDS 는 고전압까지 축적됩니다 . 그러면 Q4 가 켜지면 인덕터에 인가되는 고전압 (VDS + VIN) 으로
becomes very small. Because the falling current 인해 인덕터에 높은 상승 전류가 발생합니다 . 따라서 인덕터의 상승 및 하강 전류는 모두 크기가 커서 평균 전류를 작은
양의 값으로 유지하는 균형을 이룹니다 . 이제 Q2 가 t1 에서 갑자기 켜지면 Q2 의 VDS 는 0 으로 고정됩니다 . Q4 가
still has a large magnitude, the balance is broken 켜지면 VIN 만 인덕터에 적용됩니다 . VIN 이 매우 작아서 인덕터가 충분히 높은 전류를 축적하기에 불충분하므로
인덕터의 상승 전류가 매우 작아집니다 . 떨어지는 전류는 여전히 크기가 크기 때문에 균형이 깨지고 큰 음의 전류
and results in a large negative current spike. 스파이크가 발생합니다 .
https://www.ti.com/lit/an/slyt650/slyt650.pdf?ts=1679135242874&ref_url=https%253A%252F%252Fwww.google.com%252F

7
Totem_Pole PFC
 Totem_Pole PFC Spike Reduction
In this solution, when VAC changes from a negative to positive cy-
cle, after AC zerocrossing, Q4 first turns on with a very small
pulse width. The pulse width then gradually increases to D (the
duty cycle generated by control loop). By doing a soft-start on Q4,
정류
Q1 completely reverse recovers. Now the voltage, VDS, of Q2 PWM

gradually reduces to ground, thus the positive spike caused by sce-


nario 1 is eliminated. 정류 PWM

Once the Q4 soft-start is complete, the sync FET, Q3, starts a soft
turn-on with a tiny pulse width and gradually increases until the
pulse width reaches 1 – D. This eliminates the negative current
spike caused by scenario 2.

At the same time when the Q4 soft-start is complete and the Q3


soft-start begins, the low frequency switch, Q2, is turned on.
Since the body diode of Q1 is already recovered, there is no short-
through issue as mentioned in scenario 3.

Also, since Q3 starts with a very small pulse width, it is insufficient


for an inductor to build a negative current high enough, and thus
eliminates the current spike caused in scenario 4.

Finally, the zero-crossing detection could be mistriggered by noise.


For safety purposes, all the switches are turned off at the end of a
positive cycle. This leaves a small dead zone to prevent the input
AC from short circuiting. Note that the control loop should freeze
during this dead zone. 정류

PWM
PWM FET 먼저 Soft_Start  정류용 FET Soft_Start & Q2 On
그리도 모든 FET Off 구간을 둔다 ~! https://www.ti.com/lit/an/slyt650/slyt650.pdf?ts=1679135242874&ref_url=https%253A%25
2F%252Fwww.google.com%252F
8
Totem_Pole PFC
 Totem_Pole PFC Block - Classic boost PFC

The average inductor current shown in Figure is conducted through two diodes of the rectifier bridge at all
times, and this causes significant conduction loss, especially at higher power and low-line conditions.

https://www.infineon.com/dgdl/Infineon-Design_guide_Gallium_Nitride-CoolGaN_totem-pole_PFC_power_loss_modeling-ApplicationNotes-v01_00-EN.pdf?fileId=5546d4626d82c047016d95daec4a76
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Totem_Pole PFC
 Totem_Pole PFC Block - Bridgeless totem-pole PFC

https://www.infineon.com/dgdl/Infineon-Design_guide_Gallium_Nitride-CoolGaN_totem-pole_PFC_power_loss_modeling-ApplicationNotes-v01_00-EN.pdf?fileId=5546d4626d82c047016d95daec4a76
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Totem_Pole PFC
 Totem_Pole PFC Block - 효율비교

13%
13% 22% 9%
43%
13% 9%

22% 4%

https://www.infineon.com/dgdl/Infineon-Design_guide_Gallium_Nitride-CoolGaN_totem-pole_PFC_power_loss_modeling-ApplicationNotes-v01_00-EN.pdf?fileId=5546d4626d82c047016d95daec4a76
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Totem_Pole PFC
 Totem_Pole PFC Block - 효율비교

https://www.infineon.com/dgdl/Infineon-Design_guide_Gallium_Nitride-CoolGaN_totem-pole_PFC_power_loss_modeling-ApplicationNotes-v01_00-EN.pdf?fileId=5546d4626d82c047016d95daec4a76
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Totem_Pole PFC
 Totem_Pole PFC Block – 요구사양

https://www.infineon.com/dgdl/Infineon-Design_guide_Gallium_Nitride-CoolGaN_totem-pole_PFC_power_loss_modeling-ApplicationNotes-v01_00-EN.pdf?fileId=5546d4626d82c047016d95daec4a76
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Totem_Pole PFC
 Totem_Pole PFC Block – PFC Inductor Design

(
√ 2 ∙𝑉 𝑎 𝑐 . 𝐻𝐿
)
2

( )
1 𝑉 𝑎 𝑐 . 𝐻𝐿 1 ( 230 𝑉 )2 √ 2 ∙ 230𝑉 ∙ 1 =216 𝑢𝐻
𝐿= ∙ 1− ∙𝑇= ∙ 1−
% 𝑅𝑖𝑝𝑝𝑙𝑒 𝑃𝑜 𝑉𝑜 25 % 2500 𝑊 390 𝑉 65 𝐾𝐻𝑧

𝑉 =𝐿
𝑑𝑖
𝑑𝑡
𝐿=𝑉
𝑑𝑡
𝑑𝑖
𝐿=𝑉
∆𝑡
∆𝑖
𝐷=1 −
𝑉 𝑎𝑐 . 𝐻𝐿 ∙𝑝𝑘
𝑉𝑜
∆ 𝑡 =𝐷 ∙ 𝑇 = 1 −
𝑉𝑜 (
√ 2∙ 𝑉 𝑎𝑐 . 𝐻𝐿 ∙𝑟𝑚𝑠
∙𝑇 )
𝑉 𝑎𝑐 . 𝐻𝐿 ∙𝑟𝑚𝑠
𝑉 𝑎𝑐 . 𝐻𝐿∙ 𝑝𝑘=√ 2 ∙ 𝑉 𝑎𝑐 . 𝐻𝐿 ∙𝑟𝑚𝑠𝑉 𝑎𝑐 . 𝐻𝐿∙ 𝑟𝑚𝑠=
√2
√2 ∙ 𝑃𝑜
𝐼 𝐿 .𝑚𝑎𝑥 =
𝑉 𝑎 𝑐 . 𝐻𝐿 (
∙ 1+
% 𝑅𝑖𝑝𝑝𝑙𝑒
2 ) √ 2∙ 𝑃 𝑜 % 𝑅𝑖𝑝𝑝𝑙𝑒

𝑉 𝑎𝑐 . 𝐻𝐿 ( 2 )
= √
𝑃 𝑃 2∙ 𝑃
𝑃=𝑉 ∙ 𝐼 𝐼 = = 𝐼 𝑅𝑖𝑝𝑝𝑙𝑒
⇒ 𝑉 𝑉 𝑎𝑐 . 𝐻𝐿 ∙𝑟𝑚𝑠 𝑉 𝑎𝑐 . 𝐻𝐿 ∙𝑟𝑚𝑠
𝐼 𝑎𝑣𝑔
√2

√2 ∙ 𝑃𝑜
𝐼 𝐿 .𝑚𝑎𝑥 =
𝑉 𝑎 𝑐 . 𝐻𝐿 (
∙ 1+
% 𝑅𝑖𝑝𝑝𝑙𝑒
2
=√
230 𝑉)
2 ∙ 2500 𝑊
∙ 1+
0.25
2
=17.2 𝐴 ( )

https://www.infineon.com/dgdl/Infineon-Design_guide_Gallium_Nitride-CoolGaN_totem-pole_PFC_power_loss_modeling-ApplicationNotes-v01_00-EN.pdf?fileId=5546d4626d82c047016d95daec4a76
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Totem_Pole PFC
 Totem_Pole PFC Block – PFC Inductor Design
𝑃 𝑜 ∙ √2
𝐼 ( 𝑡 , 𝑃 𝑜 )= ∙ 𝑠𝑖𝑛 ( 2 𝜋 ∙ 𝑓 𝑙𝑖𝑛𝑒 ∙ 𝑡 )
𝑉 𝑎𝑐

𝐻 (𝑡 , 𝑃 𝑜)=
| 0.4 ∙ 𝜋 ∙ 𝑁 ∙ 𝐼 𝐿 ( 𝑡 , 𝑃 𝑜 )
𝑙 𝑒 ( 𝑐𝑚 ) |

( )
−3
0.9931+2.295 ∙ 10 ∙ 𝐻 (𝑡 , 𝑃 𝑜)
−4 2
𝜇 ( 𝑡 , 𝑃 𝑜 )= 𝜇𝑖
− 1.292 ∙10 ∙ 𝐻 (𝑡 , 𝑃 𝑜) 0.4 ∙ 𝜋 ∙ 𝑁 2 ∙ 𝜇 ( 𝑡 , 𝑃 𝑜 ) ∙ 𝐴 𝑒 ( 𝑐 𝑚2 ) 2
−7 3 𝐿 ( 𝑡 , 𝑃 𝑜 )= 𝐴𝑒 =3 ×65.6 𝑚 𝑚
+7.653 ∙ 10 ∙ 𝐻 (𝑡 , 𝑃 𝑜) 𝑙𝑒 ( 𝑐𝑚 )
−9 4
− 1.361 ∙10 ∙ 𝐻 ( 𝑡 , 𝑃𝑜)

https://www.infineon.com/dgdl/Infineon-Design_guide_Gallium_Nitride-CoolGaN_totem-pole_PFC_power_loss_modeling-ApplicationNotes-v01_00-EN.pdf?fileId=5546d4626d82c047016d95daec4a76
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Totem_Pole PFC
 Totem_Pole PFC Block – PFC Inductor Design
 Inductor copper loss
𝑃𝑜 2500 𝑊
𝐼 𝐿 .𝑟𝑚𝑠 ≅ 𝐼 𝑖𝑛.𝑟𝑚𝑠 = = =10.87 𝐴
𝑉 𝑎𝑐 . 𝐻𝐿 230 𝑉

2 2
𝑃 𝐿. 𝑐𝑜𝑛𝑑 = 𝐼 𝐿 .𝑟𝑚𝑠 ∙ 𝐷𝐶𝑅=( 10.87 𝐴 ) ∙ 0.052 Ω=6.15 𝑊

 Inductor core losses

https://www.infineon.com/dgdl/Infineon-Design_guide_Gallium_Nitride-CoolGaN_totem-pole_PFC_power_loss_modeling-ApplicationNotes-v01_00-EN.pdf?fileId=5546d4626d82c047016d95daec4a76
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Totem_Pole PFC
 Totem_Pole PFC Block – PFC Inductor Design
 Inductor core losses

https://www.infineon.com/dgdl/Infineon-Design_guide_Gallium_Nitride-CoolGaN_totem-pole_PFC_power_loss_modeling-ApplicationNotes-v01_00-EN.pdf?fileId=5546d4626d82c047016d95daec4a76
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Totem_Pole PFC
 Totem_Pole PFC Block – PFC Inductor Design
 Inductor core losses

https://www.infineon.com/dgdl/Infineon-Design_guide_Gallium_Nitride-CoolGaN_totem-pole_PFC_power_loss_modeling-ApplicationNotes-v01_00-EN.pdf?fileId=5546d4626d82c047016d95daec4a76
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Totem_Pole PFC
 Totem_Pole PFC Block – PFC Inductor Design
 Inductor core losses

https://www.infineon.com/dgdl/Infineon-Design_guide_Gallium_Nitride-CoolGaN_totem-pole_PFC_power_loss_modeling-ApplicationNotes-v01_00-EN.pdf?fileId=5546d4626d82c047016d95daec4a76
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Totem_Pole PFC
 Totem_Pole PFC Block - 효율비교

390VDC

340VDC

Hold_Up Time = 8.33ms

https://www.infineon.com/dgdl/Infineon-Design_guide_Gallium_Nitride-CoolGaN_totem-pole_PFC_power_loss_modeling-ApplicationNotes-v01_00-EN.pdf?fileId=5546d4626d82c047016d95daec4a76
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Totem_Pole PFC
 Totem_Pole PFC Coil Design

https://www.monolithicpower.com/en/how-to-avoid-inductor-saturation-in-your-power-supply-design

21
Totem_Pole PFC
 Totem_Pole PFC Coil Design

https://www.monolithicpower.com/en/how-to-avoid-inductor-saturation-in-your-power-supply-design

22
Totem_Pole PFC
 Totem_Pole PFC Coil Design

https://www.monolithicpower.com/en/how-to-avoid-inductor-saturation-in-your-power-supply-design

23
Totem_Pole PFC
 Totem_Pole PFC Coil Design

https://www.monolithicpower.com/en/how-to-avoid-inductor-saturation-in-your-power-supply-design

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Totem_Pole PFC
 Totem_Pole PFC Coil Design

Design Criteria and Input: Typical Boost Circuit Schematic:

Power: 650W
Input: 85-260 Volts DC input
Output: 370 Volts DC output
Frequency: 65 kHz

1
𝑇 = =15.4 𝑢𝑠𝑒𝑐
𝑓
650 𝑊
𝐼 𝑜𝑢𝑡 = =1.76 𝐴
370 𝑉
𝑉 𝑖𝑛
𝐷𝑚𝑎𝑥 = 1− 𝑚𝑖𝑛
= 0.77
𝑉 𝑜𝑢𝑡
𝑉 𝑖𝑛
𝐷𝑚𝑖𝑛 =1 − 𝑚𝑎𝑥
= 0.33
𝑉 𝑜𝑢𝑡

𝐷=𝐷𝑢𝑡𝑦 𝐶𝑦𝑐𝑙𝑒

https://www.mag-inc.com/Products/Powder-Cores/Kool-Mu-Cores/PFC-Boost-Design

25
Totem_Pole PFC
 Totem_Pole PFC Coil Design

Design Boost Stage:

1. Examine inductor current. 2. Determine the AC ripple permitted.


-. Inductor Current -. Max Current Ripple = 40%
This is arbitrary. The inductance and loss calcula-
𝐼 𝑎𝑣𝑔 =𝐼 𝑜𝑢𝑡 ( 1 −1 𝐷 ) tions depend on this value. Actual result will under-
shoot because the worst case inductance and ripple
do not occur together. Design can be iterated to im-
-. At Low Line Voltage prove ripple or improve cost/space.

𝐼 𝑎𝑣𝑔 =1.76 ( 1
1 − 0.77 )
=7.65 𝐴 이것은 임의적입니다 . 인덕턴스와 손실 계산은 이
값에 따라 달라집니다 . 최악의 경우 인덕턴스와
리플이 함께 발생하지 않기 때문에 실제 결과는
-. At High Line Voltage 언더슈트가 됩니다 . 리플을 개선하거나 비용 / 공간을
개선하기 위해 설계를 반복할 수 있습니다 .
𝐼 𝑎𝑣𝑔 =1.76 ( 1 − 10.30 )=2.51 𝐴

https://www.mag-inc.com/Products/Powder-Cores/Kool-Mu-Cores/PFC-Boost-Design

26
Totem_Pole PFC
 Totem_Pole PFC Coil Design

Totem_Pole Coil Design 설정 값


계산 값
▶ Design Specifications
Parameter Description Min. Typ. Max. Unit
Vin Input Voltage 86 220 260 V
Vout Output Voltage 365 370 375 V
Pout Output Power 650 W
Fsw Switching Ferquency 65000 Hz
△IL_max% Maximum Output Inductor Current Ripple 20 %
△Vo_max% Maximum Output Voltage Ripple 5 %
T 스위칭 주기 - 15.385 - usec
Iout_max Maximum Output Current 1.757 A
D_max Max On Duty (@Vin = Min) - 0.768 - -
D_min Min On Duty (@Vin = Max) - 0.297 - -

▶ Inductance Current
Parameter Description Min. Typ. Max. Unit
Inductance Average Current (@Vin = Min) - 7.558 - A
I_avg
Inductance Average Current (@Vin = Max) - 2.500 - A
△Ripple Current % Maximum Ripple Current 40 %

https://www.mag-inc.com/Products/Powder-Cores/Kool-Mu-Cores/PFC-Boost-Design

27
Totem_Pole PFC
 Totem_Pole PFC Coil Design

Design Boost Stage:

3. Inductance required to support worst-case V ripple. Highest current to be supported.

𝑡 𝑜𝑛
𝑡 𝑜𝑛+ 𝑡 𝑜𝑓𝑓 =15.4 𝑢𝑠𝑒𝑐 𝐷𝑢𝑡𝑦 𝐶𝑦𝑐𝑙𝑒 ( 𝐷 )=
15.4 𝑢𝑠

Worst case rip- Worst case rip-


ple is at high ple is at low line
line voltage voltage

https://www.mag-inc.com/Products/Powder-Cores/Kool-Mu-Cores/PFC-Boost-Design

28
Totem_Pole PFC
 Totem_Pole PFC Coil Design

▶ Ripple Current Check (허용범위 이내인지 확인, Ripple 범위 내에서 Coil이 포화하지 않는 충분한 L값 선정 필요)
Parameter Description Min. Typ. Max. Unit
V_f Diode 순방향 전압 - 1.000 - V
△I Inductance Ripple Current (@Vin = Max) - 2.000 - A
‫ܦ‬ȉܶ
L Inductance (@Vin=260V)‫ ܮ‬ൌܸ ௜௡ - 592.3 - uH
ο‫ܫ‬
△I Inductance Ripple Current (@Vin = Min) - 1.7 - A

https ://www.monolithicpower.com/en/how-to-
※ 포화되지 않도록 포화되면 과전류로 발열이 심해짐
a voi d-inductor-saturation-in-your-power-supply-
des ign
구동주파수에 따른
<== 포화되면 과전류로 발열이 심해짐
충분한 L값 설정이
중요함

I_px_max=3.50A I_px_max=8.41A

I_avg=2.50A I_avg=7.56A

I_pk_min=1.50A I_pk_min=6.71A

https://www.mag-inc.com/Products/Powder-Cores/Kool-Mu-Cores/PFC-Boost-Design

29
Totem_Pole PFC
 Totem_Pole PFC Coil Design

Design Boost Stage:

3. Inductance required to support worst-case V ripple. Highest current to be supported.

https://www.mag-inc.com/Products/Powder-Cores/Kool-Mu-Cores/PFC-Boost-Design

30
Totem_Pole PFC
 Totem_Pole PFC Coil Design

▶ Ferite Core 선택
Parameter Description Min. Typ. Max. Unit
LI^2 Ferite Core의 에너지 (@ mH) - 41.84752369 - w
Ferite Core Kool Mu 부품 번호: 0077439A7 - - -
u Core 사양에서 찾은 값 (아래 빨간선 참조, Core 마다 다름) - 60.00 - u
Ve 체적 - 21.30 - cm3
AL AL Value (Core가 정해 졌을 때 감는 수가 L과의 관계) - 135.000 -
le Max, Primary Current - 10.740 - cm
MLT The mean length per turn of wire for a core - 8.660 - cm

https://www.mag-inc.com/Products/Powder-Cores/Kool-Mu-Cores/PFC-Boost-Design

31
Totem_Pole PFC
 Totem_Pole PFC Coil Design

Design Boost Stage:

4. Core Selection Process and LI2 Product.


-. LI2=(0.598)(8.48)2=43 (Core 가 가질 수 있는 에너지 )

-. From the core selector chart below, Kool Mu part number: 0077439A7
-. μ = 60 Ve = 21.3 cm3
-. AL = 135 Aw = 4.27 cm2
-. le = 10.74 cm MLT = 8.66 cm (full)

43

https://www.mag-inc.com/Products/Powder-Cores/Kool-Mu-Cores/PFC-Boost-Design

32
Totem_Pole PFC
 Totem_Pole PFC Coil Design

Design Boost Stage:

5. Determine Number of Turns. (MLT : The mean length per turn of wire for a core)

https://electronics.stackexchange.com/questions/485659/how-to-find-mean-length-per-turn-mlt-for-magnetic-design-from-ferrite-cores-da

33
Totem_Pole PFC
 Totem_Pole PFC Coil Design

▶권선 결정
Parameter Description Min. Typ. Max. Unit
L_fix 계산된 L값의 2배로 선정 - 1184.6 - uH
‫ ܣܮ‬ȉ ܰ ଶ
계산된 Coil 권선 수 ܰ ൌ - 93.6745898 - Turn
N
선정된 Coil 권선 수 - 94 - Turn
H Core의 자화력 - 92.45 - Oer
유전율 계산된 H에 의한 유전율 (Core 사양 에서서 찾을 것) - 0.46 - -
다시 계산된 인덕턴스 (@Max 부하) - 548.72 - uH
L_fix_2nd
다시 계산된 인덕턴스 (@Min 부하) - 1184.62 - uH

0.46

93

https://www.mag-inc.com/Products/Powder-Cores/Kool-Mu-Cores/PFC-Boost-Design

34
Totem_Pole PFC
 Totem_Pole PFC Coil Design

Design Boost Stage:

5. Determine Number of Turns.


ℱ 𝑁𝐼
ℱ =𝑁𝐼 ( 기자 𝐻= =
𝑙 𝑙
[ 𝐴𝑇 /𝑚 ] ( 자화력 , AT=Amper Turn) 1[𝑂𝑒]=1,000/ 4 𝜋 [ 𝐴𝑇 /𝑚]
력)
Bm

𝐵 1 ∆𝐵
𝜇= 𝐸= 𝐿 𝐼
2

𝐻 2
H=NI
𝐵=𝜇 𝐻 𝜙=𝐵∙ 𝐴 𝑒

https://www.mag-inc.com/Products/Powder-Cores/Kool-Mu-Cores/PFC-Boost-Design

35
Totem_Pole PFC
 Totem_Pole PFC Coil Design

▶ Ripple Current Check Again ( 선정된 인덕턴스로 Ripple 전류 다시 계산함, Ripple 범위 내에서 Coil이 포화하지 않는 충분한 L값 선정 필요)
Parameter Description Min. Typ. Max. Unit
V_f Diode 순방향 전압 - 1.000 - V
△I Inductance Ripple Current (@Vin = Max) - 1.294 - A
포화 방지를 위한 자화력 재 검토 (@Ipk=3.51A) - 38.495 - Oer
H (자화력)
포화 방지를 위한 자화력 재 검토 (@Ipk=3.16A) - 34.611 - Oer

L Inductance (@Vin=260V) ‫ ܮ‬ൌ‫ܦ‬௫ ȉ‫ ܣ ܮ‬ȉ ܰ - 915.6 - uH
△I Inductance Ripple Current (@Vin = Min) - 1.829 - A

I_px_max=8.47A

I_avg=7.56A

I_px_max=3.15A I_pk_min=6.64A

I_avg=2.50A

I_pk_min=1.85A

https://www.mag-inc.com/Products/Powder-Cores/Kool-Mu-Cores/PFC-Boost-Design

36
Totem_Pole PFC
 Totem_Pole PFC Coil Design

▶ 위의 결과들을 결합하여 RMS 전류를 얻는다.


Parameter Description Min. Typ. Max. Unit
Irms RMS 전류 - 6.077 - A
‫ܮ‬ൌ ‫ܦ‬௫ ȉ‫ ܣ ܮ‬ȉ ܰ ଶ

I_avg_max=7.56A

I_avg_min=2.50A

https://www.mag-inc.com/Products/Powder-Cores/Kool-Mu-Cores/PFC-Boost-Design

37
Totem_Pole PFC
 Totem_Pole PFC Coil Design

▶ 권선 Wire 선택
Parameter Description Min. Typ. Max. Unit
Wa 선정된 Wire의 선경(면적, @#17 Gage) - 0.0122 - cm2
Fillfactor 권선 후 권선이 차지하는 면적 (%) - 26.9 - %
Wa 선정된 Wire의 선경(면적, @#16 Gage) - 0.0152 - cm2
Fillfactor 권선 후 권선이 차지하는 면적 (%) - 33.5 - %

https://www.mag-inc.com/Products/Powder-Cores/Kool-Mu-Cores/PFC-Boost-Design

38
Totem_Pole PFC
 Totem_Pole PFC Coil Design

▶ 자속밀도 계산 (Core 사양서에서 찾음)


Parameter Description Min. Typ. Max. Unit
I_(min & Max)_max 낮은 라인전압(입력전압)에서의 전류 범위 6.644 - 8.473 A
H_max 낮은 라인전압(입력전압)에서의 자화력 범위 73.9 - 94.4 Gauss
B_max 낮은 라인전압(입력전압)에서의 자속밀도 범위 4040 - 4810 Gauss
1/2*B_max B_max의 절반 (2/4분면에서만 구동) - 385.0 - Gauss
I_(min & Max)_min 높은 라인전압(입력전압)에서의 전류 범위 1.853 - 3.147 A
H_min 높은 라인전압(입력전압)에서의 자화력 범위 20.5 - 30.8 Gauss
B_min 높은 라인전압(입력전압)에서의 자속밀도 범위 1340 - 2170 Gauss
1/2*B_min B_min의 절반 (2/4분면에서만 구동) - 415.0 - Gauss

4810

4040

2170

1340

20.5 30.8 73.9 94.4

https://www.mag-inc.com/Products/Powder-Cores/Kool-Mu-Cores/PFC-Boost-Design

39
Totem_Pole PFC
 Totem_Pole PFC Coil Design

Design Boost Stage:

5. Core Loss.

https://www.mag-inc.com/Products/Powder-Cores/Kool-Mu-Cores/PFC-Boost-Design

40
Totem_Pole PFC
 Totem_Pole PFC Coil Design

▶ Core Loss (△B를 구한 후 Core 사양서를 통해 찾음)


Parameter Description Min. Typ. Max. Unit
P_core_loss Core 손실 ܲ ௖௢௥௘Ǥ௦௦ ൌ‫ܤ‬ଶ݂ ଵǤସ ܸ ௩௨ ܶ 1400.00 - 1620.000 mW

https://www.mag-inc.com/Products/Powder-Cores/Kool-Mu-Cores/PFC-Boost-Design

41

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