EXPERT SYSTEMS AND SOLUTIONS

Email: expertsyssol@gmail.com expertsyssol@yahoo.com Cell: 9952749533 www.researchprojects.info PAIYANOOR, OMR, CHENNAI Call For Research Projects Final year students of B.E in EEE, ECE, EI, M.E (Power Systems), M.E (Applied Electronics), M.E (Power Electronics) Ph.D Electrical and Electronics. Students can assemble their hardware in our Research labs. Experts will be guiding the projects.

A Spreadsheet-Based Procedure for Designing Naturally Cooled Magnetic Components

William P. Robbins Dept. of Electrical and Computer Engineering University of Minnesota May, 2002

Magnetic Component Design Problem

Challenge - conversion of component operating specs in converter circuit into magnetic component design parameters. Goal - simple, easy-to-use procedure that produces component design specs that result in an acceptable design having a minimum size, weight, and cost. Inductor electrical (e.g.converter circuit) specifications. Inductance value L Inductor currents rated peak current I, rated rms current Irms , and rated dc current (if any) Idc Operating frequency f. Allowable power dissipation in inductor or equivalently maximum surface temperature of the inductor Ts and maximum ambient temperature Ta. Transformer electrical (converter circuit) specifications. Rated rms primary voltage Vpri Rated rms primary current Ipri Turns ratio Npri/Nsec Operating frequency f Allowable power dissipation in transformer or equivalently maximum temperatures Ts and Ta Design procedure outputs. Core geometry and material. Core size (Acore , Aw) Number of turns in windings. Conductor type and area Acu. Air gap size (if needed). Ability to compare the performance of different cores and core materials for the same component. Impediments to a simple design procedure. 1. Dependence of Jrms and B on core size because of losses and magnetic saturation. 2. How to chose a core from a wide range of materials and geometries. 3. How to design low loss windings at high operating frequencies. 4. Long tedious calculations required to compare performance of different cores and materials for the same component Detailed consideration of core losses, winding losses, high frequency effects (skin and proximity effects), heat transfer mechanisms required for good design procedures.

Manual Transformer Design : Area-Product Method

Start Assemble design inputs

Assemble design inputs and compute required V-I rating S = 2 Vpri Ipri

Compute 2 V pri I

pri

Choose core geometry, core material, and winding conductor geometry.

Determine core size using assumed values of J and B

Use 2 Vpri Ipri = 4.4 f kcu Jrms Bac Aw Acore to find the required area product Aw Acore and thus the core size. Assume Jrms= 2-4 A/mm2 and Bac = 50-100 mT.

Design winding ( A cu,pri , Npri , A cu,sec , N sec )

Complete design of transformer as indicated.

Set S max desired S to

Select larger core size Yes

No

Check power dissipation and surface temperature. Excessive?.

Check power dissipation and surface temperature using assumed values of Jrmsand Bac. If dissipation or temperature are excessive, select a larger core size and repeat design steps until dissipation/temperature are acceptable.

Done

Manual Inductor Design : Area-Product Method

St rt Assem le esi i ts

Assemble design inputs and compute required L IrmsIp rating Choose core geometry, core material, and winding conductor geometry.

Compute LI rms I p = k cu rms pA wA c

Determine core si e using assumed alues of , , k cu

Use L IrmsIp = kcu Jrms Bac Aw Acore to find the required area product Aw Acore and thus the core size. Assume Jrms= 2-4 A/mm2 and Bac = 50-100 mT.

Desi n winding (Acu , )

Select l r er core si e
Y

Complete design of transformer as indicated.

No

Check ower issi tion nd surf ce tem er ture. cessi e?.

Check power dissipation and surface temperature using assumed values of Jrmsand Bac. If dissipation or temperature are excessive, select a larger core size and repeat design steps until dissipation/temperature are acceptable.

Set irgap. Re-adjust A and if needed.

Set airgap to achieve Bp at Ip and adjust A and N if needed.

one

Critique of Area-Product Method

Procedure ignores dependence of J and B on core size. Assumed values of J and B are smaller than necessary for components with small electrical ratings and results in overly large components for the small electrical ratings range. Assumed values of J and B are larger than allowable for components with large electrical ratings and results in components that are too small for the large electrical rating range.

Large number of cores and core materials available makes it difficult for inexperienced designers to make a reasonable first choice of core and core material for a particular application. Results in multiple manual and time-consuming design iterations.

Comparison of designs using different core geometries and materials (highly desirable if the smallest sized component is to be found) impractical. Requires detailed information on all cores and core materials of interest which may be difficult to find in a short time. Requires many lengthy manual(and hence error-prone) calculations.

Manual area-product procedure best suited for one-off design situations or where rapid construction and testing is more important than cost, size, or weight considerations.

Relating J and B to Core Size Quantitatively

Assume simple thermal model of transformer (core+winding). 1. Losses uniformly distributed over entire transformer volume. Psp,core = Psp,winding = Psp 2. No significant temperature gradients in transformer interior. Tinterior Tsurface = Ts
Psp = Ts - Ta U,sa( c) ; U,sa h/As
B Bs Minor hystersis loop H

h convective heat trans er coe icient 10 r -m2/W As sur ace area o trans ormer (core inding). stimate using core dimensions and simple geometric considerations. Uncertain accuracy o h and other heat trans er parameters do not usti y more exact thermal modeling o trans ormer.

Psp,core

Psp

kcu Vcu (Jrms)2

or Jrms

Psp kcu Vcu

- Bs

[Psp]1/b Psp,core Psp Kc a [ ac]b or ac [Kc]1/b[ ]a/b Kc,a,b constants o selected errite material.

Example: E-core Geometric Parameters

A D

radiu = 1 (E F) 4

E-core dimensions Two core halves make up a complete double-E core. Core volume Vm, core area Am, and mean path length lm given in core spec sheet. Winding volume Vw, winding area Aw, and mean turn length lw without coil former generally not given.

Winding area Aw = 2D(E-F)/2 = D(E-F) Mean turn length lw = 2(F+C)+0.5 (E-F). See figure to left. Winding volume Vw = Aw lw Similar formulas for all cores in database. Winding parameters of coil formers used in spreadsheet where available.

Example: E-core Transformer Surface Area As

2B C 1 (E-F) 2
As sur ace area o assembled core plus sur ace area o inding not included in core sur ace area. Core sur ace area 4A 4 C 2AC inding not Sur ace area o included in core sur ace area 4 {0.5}( - ) 4{2 (0.5)( - )} 2 ( - ) 4 ( - ) 2( - )( 2 ) As 4A 4 C 2( - )( 2 ) 2AC

Rounded corners ignored in surface area estimate 1 (E-F) 2 2D

Details of Interactive Transformer Core Database Calculations

User inputs: Vpri, Ipri, Vsec f, Ts, Ta, and kcu for transformer; L, Irms, Ip, f, Ts, Ta, and kcu for inductor. Stored information (static, independent of converter requirements) Core dimensions, Aw, Ac r , Vc, Vw, surface area, mean turn length, mean magnetic path length, etc. Quantitative core loss formulas for all materials of interest including approximate temperature dependence.

Spreadsheet calculates capabilities of all cores in database 1. Converter-required transformer V-I rating = Vpri Ipri or inductor stored energy rating = L IrmsIp. 2. Compute allowable specific power dissipation Psp = [Ts - Ta] /{ RUsa [Vc + Vw ]}. RUsa = h/As 3. Compute allowable flux density Psp = k fb [Bac]d and current density Psp = kcu Vcu {Jrms}2.
r

Calculation of transformer parameters. 1. Number of primary turns Npri = Vpri /{2 f AcpreBac} and secondary turns Nsec = Vsec /{2 f AcpreBac} 2. Winding conductor areas assuming low frequencies or use of Leitz wire Acu,pri = [kcuAw]/[2 Npri] and Acu,sec = [kcuAw]/[2 Nsec]

4. Compute core capabilities 4.4 f kcu Aw Ac

Bac Jrms (transformer) or kcu Aw Ac

Bp Jrms (inductor)

Details of Interactive Transformer Core Database Calculations (cont.)

. 3. Leakage inductance Lleak= {o{Npri}2 lw bw}/ {3 p2 hw} (E-core formula): Similar formulas for other cores.

Calculation of inductor parameters 1. Conductor area Acu= Irms/Jrms; number of turns N = kcuAw/ Acu 2. Set airgap length so that at Ip total flux density = Bp. Assume effectivedimensions of gap area equal dimensions of core plus g, where g is the airgap length.

Spreadsheet examines capabilities of all cores and displays the smallest size core of each different geometry that meets the requirements on the input-output page (INOUT) of the spreadsheet.

Transformer outputs: core number, current and flux densities, total volume, conductor areas, number of primary and secondary turns, leakage inductance, and efficiency (power out)/(power in).

Inductor outputs: core number, current and flux densities, total volume, conductor area, number of turns, and airgap length.

Input - Output Section of Inductor Design Tool

Design Inputs Inductance [H] 39 Idc [A] 0.001
0

kcu 0.4
40

Ta ( rC) 35

Ts (rC) 70

Freq. [kHz] 40

Material 3F3 3F3

Iac(b-p) [A] 6.700

67

Ipeak [A] 6.701

Irms [A] 3.868

Trianglar Waveform Assumed for AC current

LIp Irms [milliJoules]

1.01 H [mm] 0.37314377

DESIGN OUTPUTS
Skin, Prox.

Core Type E-c r EC-c r EFD-c r EP-c r ER-c r ETD-c r PM-c r Potcor PQ-cor RMI-cor U-cor

Core # E25/13/7 EC35 # /A # /A ER28 ETD29 PM 50/39 P30/19 PQ26/25 RM10/I U20/16/7

LIpIrms [ illi l s] 1.12 2.26 0.00 0.00 1.37 1.71 12.38 1.36 1.39 1.21 1.18

Jrms
[A/mm
2

Bpeak
] [mT]

N
[#]

Acu
[mm ]
2

Airgap
[mm ]

Effects?

Vc+Vw [cm ]
3

Notes
 
Any row aving multipl c ll ntri s of # /A indicat s t cor in

negative numbers or # UM! Indicate numerical problems in t e calculations for t at cell. Entries in suc cells s ould be ignored but t e rest of t e entries in t at row are still reliable. Airgap calculations are t e most likely to ave problems.

t at row cannot meet t e input specifications. Cell entries wit

  

3.55 3.28 # /A # /A 2.27 3.10 2.33 2.57 2.41 3.51 3.32

211.49 199.54 # /A # /A 151.76 191.00 154.81 166.47 193.56 209.65 201.28

21.97 15.54 # /A # /A 21.16 18.00 4.56 11.46 11.25 12.90 23.19

1.09 1.18 # /A # /A 1.70 1.25 1.66 1.50 1.60 1.10 1.16

1.15 0.61 # /A # /A 1.44 0.93 0.20 0.66 0.49 0.54 1.10

YES YES # /A # /A YES YES YES YES YES YES YES

6.47 11.97 # /A # /A 12.55 10.41 75.41 10.02 9.21 6.54 8.09

Input - Output Section of Transformer Design Tool

Design Inputs
Throughput

kcu 0.67
67

Ta (C) 24

Ts (C) 93

Freq. [kHz] 101

Material 3C94 3C94

Vpri,rms 107

Ipri,rms 10.0
100

Vsec,rms 110

Isec,rms 9.73

Power 2140

H [cm] 0.02348256

Design

Outputs
Skin, Prox. Effects? [nH] Lleakage 167.2

Core Type E-core EC-core EFD-core EP-core ER-core ETD-core PM-core Potcore PQ-core RM-I core U-core

Core # E41/17/12 EC41 # /A # /A ER40 ETD39 PM 50/39 P42/29 PQ35/35 RM14/I U/33/22/9

V-A Rating
[watts]

Jrms
[A/mm
2

Bac
] [mT]

Npri
[#]

Nsec
[#]

Acu,pri
[mm ]
2

Acu,sec
[mm ]
2

Vc+Vw [cm ]
3

Efficiency [%] 99.70% 99.72% # /A # /A 99.81% 99.73% 99.34% 99.77% 99.72% 99.72% 99.63%

Notes
Any row aving a cell entry of # /A indicates t at t e core in t at row cannot meet t e input specifications.

 

 

 

 

 

 

 

 

 

 

2665 2283 0 0 2142 2459 7578 2901 3243 2721 2679

3 3 # /A # /A 2 3 3 2 3 3 3

135 142 # /A # /A 104 129 117 111 119 135 123

11.4 13.9 # /A # /A 15.4 14.7 5.5 8.1 10.6 8.9 22.3

11.7 14.3 # /A # /A 15.8 15.2 5.6 8.3 10.9 9.1 23.0

3.26068 3.0705642 # /A # /A 4.654855 3.4657303 3.9545774 4.2421993 3.8835429 3.2577377 3.693498

3.1717523 2.9868215 # /A # /A 4.5279045 3.3712104 3.8467253 4.126503 3.7776281 3.1688903 3.5927662

YES YES # /A # /A YES YES YES YES YES YES YES

22.9

19 # /A # /A 30 24 75 30 30 22 37

141 # /A # /A 182 183 90 104 124 79 1030

 

Example: E Core V-A Capability vs Frequency

Curve labels refer to Phillips E core designations. 3C80 ferrite ; (T = 65 SC ; kcu = 0.2
10000
E80/38/20 E71/33/32 E65/32/27

9000 8000 7000 6000

E55/28/25

5000 4000 3000 2000 1000 0 20 40 60 Frequency [kHz] 80

E55/28/21 E46/23/30 E56/24/19 E50/27/15 E42/21/20

100

120

Example: Selected Material Performance Factors

50 45 Experiment Cur efit

40 4F1 35 3F4 30

25

20

15 N61 10 3C30 5 N41

0 10 100 Fr 1000 10000

z]

&

! %$ #"