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Fundamentals of Power Electronics Chapter 14: Inductor design1
Chapter 14 Inductor Design
14.1 Filter inductor design constraints
14.2 A step-by-step design procedure
14.3 Multiple-winding magnetics design using the
Kg method
14.4 Examples
14.5 Summary of key points
Fundamentals of Power Electronics Chapter 14: Inductor design2
14.1 Filter inductor design constraints
Pcu = Irms
2
R
Objective:
Design inductor having a given inductance L,
which carries worst-case current Imax without saturating,
and which has a given winding resistance R, or, equivalently,
exhibits a worst-case copper loss of
L
R
i(t)
+
–
L
i(t)
i(t)
t0 DTs
Ts
I ∆iL
Example: filter inductor in CCM buck converter
Fundamentals of Power Electronics Chapter 14: Inductor design3
Assumed filter inductor geometry
Solve magnetic circuit:
Air gap
reluctance
Rg
n
turns
i(t)
Φ
Core reluctance Rc
+
v(t)
– +
–
ni(t) Φ(t)
Rc
Rg
Fc
+ –
Rc =
lc
µcAc
Rg =
lg
µ0Ac
ni = Φ Rc + Rg
ni ≈ ΦRg
Usually Rc < Rg and hence
Fundamentals of Power Electronics Chapter 14: Inductor design4
14.1.1 Constraint: maximum flux density
Given a peak winding current Imax, it is desired to operate the core flux
density at a peak value Bmax. The value of Bmax is chosen to be less
than the worst-case saturation flux density Bsat of the core material.
From solution of magnetic circuit:
Let I = Imax and B = Bmax :
This is constraint #1. The turns ratio n and air gap length lg are
unknown.
ni = BAcRg
nImax = Bmax Ac Rg = Bmax
lg
µ0
Fundamentals of Power Electronics Chapter 14: Inductor design5
14.1.2 Constraint: inductance
Must obtain specified inductance L. We know that the inductance is
This is constraint #2. The turns ratio n, core area Ac, and air gap length
lg are unknown.
L = n2
Rg
=
µ0Ac n2
lg
Fundamentals of Power Electronics Chapter 14: Inductor design6
14.1.3 Constraint: winding area
core window
area WA
wire bare area
AW
core
Wire must fit through core window (i.e., hole in center of core)
nAW
Total area of
copper in window:
KuWA
Area available for winding
conductors:
Third design constraint:
KuWA ≥ nAW
Fundamentals of Power Electronics Chapter 14: Inductor design7
The window utilization factor Ku
also called the “fill factor”
Ku is the fraction of the core window area that is filled by copper
Mechanisms that cause Ku to be less than 1:
• Round wire does not pack perfectly, which reduces Ku by a
factor of 0.7 to 0.55 depending on winding technique
• Insulation reduces Ku by a factor of 0.95 to 0.65, depending on
wire size and type of insulation
• Bobbin uses some window area
• Additional insulation may be required between windings
Typical values of Ku :
0.5 for simple low-voltage inductor
0.25 to 0.3 for off-line transformer
0.05 to 0.2 for high-voltage transformer (multiple kV)
0.65 for low-voltage foil-winding inductor
Fundamentals of Power Electronics Chapter 14: Inductor design8
14.1.4 Winding resistance
The resistance of the winding is
where is the resistivity of the conductor material, lb is the length of
the wire, and AW is the wire bare area. The resistivity of copper at
room temperature is 1.724 10–6 -cm. The length of the wire comprising
an n-turn winding can be expressed as
where (MLT) is the mean-length-per-turn of the winding. The mean-
length-per-turn is a function of the core geometry. The above
equations can be combined to obtain the fourth constraint:
R = ρ
n (MLT)
AW
R = ρ
lb
AW
lb = n(MLT)
Fundamentals of Power Electronics Chapter 14: Inductor design9
14.1.5 The core geometrical constant Kg
The four constraints:
R = ρ
n (MLT)
AW
KuWA ≥ nAW
These equations involve the quantities
Ac, WA, and MLT, which are functions of the core geometry,
Imax, Bmax , µ0, L, Ku, R, and , which are given specifications or
other known quantities, and
n, lg, and AW, which are unknowns.
Eliminate the three unknowns, leading to a single equation involving
the remaining quantities.
nImax = Bmax Ac Rg = Bmax
lg
µ0
L = n2
Rg
=
µ0Ac n2
lg
Fundamentals of Power Electronics Chapter 14: Inductor design10
Core geometrical constant Kg
Ac
2
WA
(MLT)
≥
ρL2
Imax
2
Bmax
2
RKu
Elimination of n, lg, and AW leads to
• Right-hand side: specifications or other known quantities
• Left-hand side: function of only core geometry
So we must choose a core whose geometry satisfies the above
equation.
The core geometrical constant Kg is defined as
Kg =
Ac
2
WA
(MLT)
Fundamentals of Power Electronics Chapter 14: Inductor design11
Discussion
Kg =
Ac
2
WA
(MLT)
≥
ρL2
Imax
2
Bmax
2
RKu
Kg is a figure-of-merit that describes the effective electrical size of magnetic
cores, in applications where the following quantities are specified:
• Copper loss
• Maximum flux density
How specifications affect the core size:
A smaller core can be used by increasing
Bmax use core material having higher Bsat
R allow more copper loss
How the core geometry affects electrical capabilities:
A larger Kg can be obtained by increase of
Ac more iron core material, or
WA larger window and more copper
Fundamentals of Power Electronics Chapter 14: Inductor design12
14.2 A step-by-step procedure
The following quantities are specified, using the units noted:
Wire resistivity ( -cm)
Peak winding current Imax (A)
Inductance L (H)
Winding resistance R ( )
Winding fill factor Ku
Core maximum flux density Bmax (T)
The core dimensions are expressed in cm:
Core cross-sectional area Ac (cm2)
Core window area WA (cm2)
Mean length per turn MLT (cm)
The use of centimeters rather than meters requires that appropriate
factors be added to the design equations.
Fundamentals of Power Electronics Chapter 14: Inductor design13
Determine core size
Kg ≥
ρL2
Imax
2
Bmax
2
RKu
108
(cm5
)
Choose a core which is large enough to satisfy this inequality
(see Appendix D for magnetics design tables).
Note the values of Ac, WA, and MLT for this core.
Fundamentals of Power Electronics Chapter 14: Inductor design14
Determine air gap length
with Ac expressed in cm2. µ0 = 4 10–7 H/m.
The air gap length is given in meters.
The value expressed above is approximate, and neglects fringing flux
and other nonidealities.
lg =
µ0LImax
2
Bmax
2
Ac
104
(m)
Fundamentals of Power Electronics Chapter 14: Inductor design15
AL
Core manufacturers sell gapped cores. Rather than specifying the air
gap length, the equivalent quantity AL is used.
AL is equal to the inductance, in mH, obtained with a winding of 1000
turns.
When AL is specified, it is the core manufacturer’s responsibility to
obtain the correct gap length.
The required AL is given by:
AL =
10Bmax
2
Ac
2
LImax
2 (mH/1000 turns)
L = AL n2
10– 9
(Henries)
Units:
Ac cm2,
L Henries,
Bmax Tesla.
Fundamentals of Power Electronics Chapter 14: Inductor design16
Determine number of turns n
n =
LImax
Bmax Ac
104
Fundamentals of Power Electronics Chapter 14: Inductor design17
Evaluate wire size
AW ≤
KuWA
n
(cm2
)
Select wire with bare copper area AW less than or equal to this value.
An American Wire Gauge table is included in Appendix D.
As a check, the winding resistance can be computed:
R =
ρn (MLT)
Aw
(Ω)
Fundamentals of Power Electronics Chapter 14: Inductor design18
14.3 Multiple-winding magnetics design
using the Kg method
The Kg design method can be extended to multiple-
winding magnetic elements such as transformers and
coupled inductors.
This method is applicable when
– Copper loss dominates the total loss (i.e. core loss is
ignored), or
– The maximum flux density Bmax is a specification rather than
a quantity to be optimized
To do this, we must
– Find how to allocate the window area between the windings
– Generalize the step-by-step design procedure
Fundamentals of Power Electronics Chapter 14: Inductor design19
14.3.1 Window area allocation
n1 : n2
: nk
rms current
I1
rms current
I2
rms current
Ik
v1(t)
n1
=
v2(t)
n2
= =
vk(t)
nk
Core
Window area WA
Core mean length
per turn (MLT)
Wire resistivity ρ
Fill factor Ku
Given: application with k windings
having known rms currents and
desired turns ratios
Q: how should the window
area WA be allocated among
the windings?
Fundamentals of Power Electronics Chapter 14: Inductor design20
Allocation of winding area
Total window
area WA
Winding 1 allocation
α1WA
Winding 2 allocation
α2
WA
etc.
{
{
0 < αj < 1
α1 + α2 + + αk = 1
Fundamentals of Power Electronics Chapter 14: Inductor design21
Copper loss in winding j
Copper loss (not accounting for proximity loss) is
Pcu,j = I j
2
Rj
Resistance of winding j is
with
AW,j =
WAKuαj
nj
length of wire, winding j
wire area, winding j
Hence
Rj = ρ
l j
AW,j
l j = nj (MLT)
Rj = ρ
n j
2
(MLT)
WAKuα j
Pcu,j =
n j
2
i j
2
ρ(MLT)
WAKuα j
Fundamentals of Power Electronics Chapter 14: Inductor design22
Total copper loss of transformer
Sum previous expression over all windings:
Pcu,tot = Pcu,1 + Pcu,2 + + Pcu,k =
ρ (MLT)
WAKu
nj
2
I j
2
αj
Σj = 1
k
Need to select values for 1, 2, …, k such that the total copper loss
is minimized
Fundamentals of Power Electronics Chapter 14: Inductor design23
Variation of copper losses with 1
For 1 = 0: wire of
winding 1 has zero area.
Pcu,1 tends to infinity
For 1 = 1: wires of
remaining windings have
zero area. Their copper
losses tend to infinity
There is a choice of 1
that minimizes the total
copper lossα1
Copper
loss
0 1
Pcu,tot
Pcu,1
P cu,2+
P
cu,3+...+P
cu,k
Fundamentals of Power Electronics Chapter 14: Inductor design24
Method of Lagrange multipliers
to minimize total copper loss
Pcu,tot = Pcu,1 + Pcu,2 + + Pcu,k =
ρ (MLT)
WAKu
nj
2
I j
2
αj
Σj = 1
k
subject to the constraint
α1 + α2 + + αk = 1
Define the function
f(α1, α2, , αk, ξ) = Pcu,tot(α1, α2, , αk) + ξ g(α1, α2, , αk)
Minimize the function
where
g(α1, α2, , αk) = 1 – αjΣj = 1
k
is the constraint that must equal zero
and is the Lagrange multiplier
Fundamentals of Power Electronics Chapter 14: Inductor design25
Lagrange multipliers
continued
Optimum point is solution of
the system of equations
∂ f(α1, α2, , αk,ξ)
∂α1
= 0
∂ f(α1, α2, , αk,ξ)
∂α2
= 0
∂ f(α1, α2, , αk,ξ)
∂αk
= 0
∂ f(α1, α2, , αk,ξ)
∂ξ
= 0
Result:
ξ =
ρ (MLT)
WAKu
njIjΣj = 1
k 2
= Pcu,tot
αm =
nmIm
njIjΣn = 1
∞
An alternate form:
αm =
VmIm
VjIjΣn = 1
∞
Fundamentals of Power Electronics Chapter 14: Inductor design26
Interpretation of result
αm =
VmIm
VjIjΣn = 1
∞
Apparent power in winding j is
Vj Ij
where Vj is the rms or peak applied voltage
Ij is the rms current
Window area should be allocated according to the apparent powers of
the windings
Fundamentals of Power Electronics Chapter 14: Inductor design27
Ii1(t)
n1
turns {
}n2 turns
}n2 turns
i2(t)
i3(t)
Example
PWM full-bridge transformer
• Note that waveshapes
(and hence rms values)
of the primary and
secondary currents are
different
• Treat as a three-
winding transformer
–
n2
n1
I
t
i1(t)
0 0
n2
n1
I
i2(t)
I
0.5I 0.5I
0
i3(t)
I
0.5I 0.5I
0
0 DTs Ts 2TsTs +DTs
Fundamentals of Power Electronics Chapter 14: Inductor design28
Expressions for RMS winding currents
I1 = 1
2Ts
i1
2
(t)dt
0
2Ts
=
n2
n1
I D
I2 = I3 = 1
2Ts
i2
2
(t)dt
0
2Ts
= 1
2
I 1 + D
see Appendix A
–
n2
n1
I
t
i1(t)
0 0
n2
n1
I
i2(t)
I
0.5I 0.5I
0
i3(t)
I
0.5I 0.5I
0
0 DTs Ts 2TsTs +DTs
Fundamentals of Power Electronics Chapter 14: Inductor design29
Allocation of window area: αm =
VmIm
VjIjΣn = 1
∞
α1 = 1
1 + 1 + D
D
α2 = α3 = 1
2
1
1 + D
1 + D
Plug in rms current expressions. Result:
Fraction of window area
allocated to primary
winding
Fraction of window area
allocated to each
secondary winding
Fundamentals of Power Electronics Chapter 14: Inductor design30
Numerical example
Suppose that we decide to optimize the transformer design at the
worst-case operating point D = 0.75. Then we obtain
α1 = 0.396
α2 = 0.302
α3 = 0.302
The total copper loss is then given by
Pcu,tot =
ρ(MLT)
WAKu
njIjΣj = 1
3 2
=
ρ(MLT)n2
2
I2
WAKu
1 + 2D + 2 D(1 + D)
Fundamentals of Power Electronics Chapter 14: Inductor design31
14.3.2 Coupled inductor design constraints
n1 : n2
: nk
R1 R2
Rk
+
v1(t)
–
+
v2(t)
–
+
vk(t)
–
i1(t) i2(t)
ik(t)
LM
iM(t)
+
–n1iM(t) Φ(t)
Rc
Rg
Consider now the design of a coupled inductor having k windings. We want
to obtain a specified value of magnetizing inductance, with specified turns
ratios and total copper loss.
Magnetic circuit model:
Fundamentals of Power Electronics Chapter 14: Inductor design32
Relationship between magnetizing
current and winding currents
n1 : n2
: nk
R1 R2
Rk
+
v1(t)
–
+
v2(t)
–
+
vk(t)
–
i1(t) i2(t)
ik(t)
LM
iM(t)
iM(t) = i1(t) +
n2
n1
i2(t) + +
nk
n1
ik(t)
Solution of circuit model, or by use of
Ampere’s Law:
Fundamentals of Power Electronics Chapter 14: Inductor design33
Solution of magnetic circuit model:
Obtain desired maximum flux density
+
–n1iM(t) Φ(t)
Rc
Rg
n1iM(t) = B(t)AcRg
Assume that gap reluctance is much
larger than core reluctance:
Design so that the maximum flux density Bmax is equal to a specified value
(that is less than the saturation flux density Bsat ). Bmax is related to the
maximum magnetizing current according to
n1IM,max = BmaxAcRg = Bmax
lg
µ0
Fundamentals of Power Electronics Chapter 14: Inductor design34
Obtain specified magnetizing inductance
LM =
n1
2
Rg
= n1
2 µ0 Ac
lg
By the usual methods, we can solve for the value of the magnetizing
inductance LM (referred to the primary winding):
Fundamentals of Power Electronics Chapter 14: Inductor design35
Copper loss
Allocate window area as described in Section 14.3.1. As shown in that
section, the total copper loss is then given by
Pcu =
ρ(MLT)n1
2
Itot
2
WAKu
Itot =
nj
n1
I jΣj = 1
k
with
Fundamentals of Power Electronics Chapter 14: Inductor design36
Eliminate unknowns and solve for Kg
Pcu =
ρ(MLT)LM
2
Itot
2
IM,max
2
Bmax
2
Ac
2
WAKu
Eliminate the unknowns lg and n1:
Rearrange equation so that terms that involve core geometry are on
RHS while specifications are on LHS:
Ac
2
WA
(MLT)
=
ρLM
2
Itot
2
IM,max
2
Bmax
2
KuPcu
The left-hand side is the same Kg as in single-winding inductor design.
Must select a core that satisfies
Kg ≥
ρLM
2
Itot
2
IM,max
2
Bmax
2
KuPcu
Fundamentals of Power Electronics Chapter 14: Inductor design37
14.3.3 Step-by-step design procedure:
Coupled inductor
The following quantities are specified, using the units noted:
Wire resistivity ( -cm)
Total rms winding currents (A) (referred to winding 1)
Peak magnetizing current IM, max (A) (referred to winding 1)
Desired turns ratios n2/n1. n3/n2. etc.
Magnetizing inductance LM (H) (referred to winding 1)
Allowed copper loss Pcu (W)
Winding fill factor Ku
Core maximum flux density Bmax (T)
The core dimensions are expressed in cm:
Core cross-sectional area Ac (cm2)
Core window area WA (cm2)
Mean length per turn MLT (cm)
The use of centimeters rather than meters requires that appropriate factors be added to the design equations.
Itot =
nj
n1
I jΣj = 1
k
Fundamentals of Power Electronics Chapter 14: Inductor design38
1. Determine core size
Kg ≥
ρLM
2
Itot
2
IM,max
2
Bmax
2
Pcu Ku
108
(cm5)
Choose a core that satisfies this inequality. Note the values of Ac, WA,
and MLT for this core.
The resistivity of copper wire is 1.724 · 10–6 cm at room
temperature, and 2.3 · 10–6 cm at 100˚C.
Fundamentals of Power Electronics Chapter 14: Inductor design39
2. Determine air gap length
lg =
µ0LM IM,max
2
Bmax
2
Ac
104
(m)
(value neglects fringing flux, and a longer gap may be required)
The permeability of free space is µ0 = 4 · 10–7 H/m
Fundamentals of Power Electronics Chapter 14: Inductor design40
3. Determine number of turns
For winding 1:
n1 =
LM IM,max
BmaxAc
104
For other windings, use the desired turns ratios:
n2 =
n2
n1
n1
n3 =
n3
n1
n1
Fundamentals of Power Electronics Chapter 14: Inductor design41
4. Evaluate fraction of window area
allocated to each winding
α1 =
n1I1
n1Itot
α2 =
n2I2
n1Itot
αk =
nkIk
n1Itot
Total window
area WA
Winding 1 allocation
α1WA
Winding 2 allocation
α2WA
etc.
{
{
0 < αj < 1
α1 + α2 + + αk = 1
Fundamentals of Power Electronics Chapter 14: Inductor design42
5. Evaluate wire sizes
Aw1 ≤
α1KuWA
n1
Aw2 ≤
α2KuWA
n2
See American Wire Gauge (AWG) table at end of Appendix D.
Fundamentals of Power Electronics Chapter 14: Inductor design43
14.4 Examples
14.4.1 Coupled Inductor for a Two-Output Forward
Converter
14.4.2 CCM Flyback Transformer
Fundamentals of Power Electronics Chapter 14: Inductor design44
14.4.1 Coupled Inductor for a Two-Output
Forward Converter
n1
+
v1
–
n2
turns
i1
+
v2
–
i2
+
–vg
Output 1
28 V
4 A
Output 2
12 V
2 Afs = 200 kHz
The two filter inductors can share the same core because their applied
voltage waveforms are proportional. Select turns ratio n2/n1
approximately equal to v2/v1 = 12/28.
Fundamentals of Power Electronics Chapter 14: Inductor design45
Coupled inductor model and waveforms
n1:n2
+
v1
–
i1
+
v2
–
i2
LM
iM
Coupled
inductor
model
vM
+ –
iM(t)
vM(t)
IM
0
0
– V1
∆iM
D′Ts
Secondary-side circuit, with coupled
inductor model
Magnetizing current and voltage
waveforms. iM(t) is the sum of
the winding currents i1(t) + i2(t).
Fundamentals of Power Electronics Chapter 14: Inductor design46
Nominal full-load operating point
n1
+
v1
–
n2
turns
i1
+
v2
–
i2
+
–vg
Output 1
28 V
4 A
Output 2
12 V
2 Afs = 200 kHz
Design for CCM
operation with
D = 0.35
iM = 20% of IM
fs = 200 kHz
DC component of magnetizing current is
IM = I1 +
n2
n1
I2
= (4 A) + 12
28
(2 A)
= 4.86 A
Fundamentals of Power Electronics Chapter 14: Inductor design47
Magnetizing current ripple
iM(t)
vM(t)
IM
0
0
– V1
∆iM
D′Ts
∆iM =
V1D′Ts
2LM
To obtain
iM = 20% of IM
choose
LM =
V1D′Ts
2∆iM
=
(28 V)(1 – 0.35)(5 µs)
2(4.86 A)(20%)
= 47 µH
This leads to a peak magnetizing
current (referred to winding 1) of
IM,max = IM + ∆iM = 5.83 A
Fundamentals of Power Electronics Chapter 14: Inductor design48
RMS winding currents
Since the winding current ripples are small, the rms values of the
winding currents are nearly equal to their dc comonents:
I1 = 4 A I2 = 2 A
Hence the sum of the rms winding currents, referred to the primary, is
Itot = I1 +
n2
n1
I2 = 4.86 A
Fundamentals of Power Electronics Chapter 14: Inductor design49
Evaluate Kg
The following engineering choices are made:
– Allow 0.75 W of total copper loss (a small core having
thermal resistance of less than 40 ˚C/W then would have a
temperature rise of less than 30 ˚C)
– Operate the core at Bmax = 0.25 T (which is less than the
ferrite saturation flux density of 0.3 ot 0.5 T)
– Use fill factor Ku = 0.4 (a reasonable estimate for a low-
voltage inductor with multiple windings)
Evaluate Kg:
Kg ≥
(1.724 ⋅ 10– 6
Ω – cm)(47 µH)2
(4.86 A)2
(5.83 A)2
(0.25 T)2
(0.75 W)(0.4)
108
= 16 ⋅ 10– 3
cm5
Fundamentals of Power Electronics Chapter 14: Inductor design50
Select core
A1
2D
It is decided to use a ferrite PQ core. From
Appendix D, the smallest PQ core having
Kg 16 · 10–3 cm5 is the PQ 20/16, with Kg =
22.4 · 10–3 cm5 . The data for this core are:
Ac = 0.62 cm2
WA = 0.256 cm2
MLT = 4.4 cm
Fundamentals of Power Electronics Chapter 14: Inductor design51
Air gap length
lg =
µ0LM IM,max
2
Bmax
2
Ac
104
=
(4π ⋅ 10– 7
H/m)(47 µH)(5.83 A)2
(0.25 T)2
(0.62 cm2)
104
= 0.52 mm
Fundamentals of Power Electronics Chapter 14: Inductor design52
Turns
n1 =
LM IM,max
BmaxAc
104
=
(47 µH)(5.83 A)
(0.25 T)(0.62 cm2)
104
= 17.6 turns
n2 =
n2
n1
n1
=
12
28
(17.6)
= 7.54 turns
Let’s round off to
n1 = 17 n2 = 7
Fundamentals of Power Electronics Chapter 14: Inductor design53
Wire sizes
Allocation of window area:
α1 =
n1I1
n1Itot
=
(17)(4 A)
(17)(4.86 A)
= 0.8235
α2 =
n2I2
n1Itot
=
(7)(2 A)
(17)(4.86 A)
= 0.1695
Aw1 ≤
α1KuWA
n1
=
(0.8235)(0.4)(0.256cm2)
(17)
= 4.96 ⋅ 10– 3
cm2
use AWG #21
Aw2 ≤
α2KuWA
n2
=
(0.1695)(0.4)(0.256cm2)
(7)
= 2.48 ⋅ 10– 3
cm2
use AWG #24
Determination of wire areas and AWG (from table at end of Appendix D):
Fundamentals of Power Electronics Chapter 14: Inductor design54
14.4.2 Example 2: CCM flyback transformer
+
–
LM
+
V
–
Vg
Q1
D1
n1 : n2
C
Transformer model
iM
i1
R
+
vM
–
i2
vM(t)
0
Vg
DTs
iM(t)
IM
0
∆iM
i1(t)
IM
0
i2(t)
IM
0
n1
n2
Fundamentals of Power Electronics Chapter 14: Inductor design55
Specifications
Input voltage Vg = 200V
Output (full load) 20 V at 5 A
Switching frequency 150 kHz
Magnetizing current ripple 20% of dc magnetizing current
Duty cycle D = 0.4
Turns ratio n2/n1 = 0.15
Copper loss 1.5 W
Fill factor Ku = 0.3
Maximum flux density Bmax = 0.25 T
Fundamentals of Power Electronics Chapter 14: Inductor design56
Basic converter calculations
IM =
n2
n1
1
D′
V
R
= 1.25 A
∆iM = 20% IM = 0.25 A
IM,max = IM + ∆iM = 1.5 A
Components of magnetizing
current, referred to primary:
Choose magnetizing inductance:
LM =
Vg DTs
2∆iM
= 1.07 mH
RMS winding currents:
I1 = IM D 1 + 1
3
∆iM
IM
2
= 0.796 A
I2 =
n1
n2
IM D′ 1 + 1
3
∆iM
IM
2
= 6.50 A
Itot = I1 +
n2
n1
I2 = 1.77 A
Fundamentals of Power Electronics Chapter 14: Inductor design57
Choose core size
Kg ≥
ρLM
2
Itot
2
IM,max
2
Bmax
2
Pcu Ku
108
=
1.724 ⋅ 10– 6
Ω-cm 1.07 ⋅ 10– 3
H
2
1.77 A
2
1.5 A
2
0.25 T
2
1.5 W 0.3
108
= 0.049 cm5
The smallest EE core that satisfies
this inequality (Appendix D) is the
EE30.
A
Fundamentals of Power Electronics Chapter 14: Inductor design58
Choose air gap and turns
lg =
µ0LM IM,max
2
Bmax
2
Ac
104
=
4π ⋅ 10– 7
H/m 1.07 ⋅ 10– 3
H 1.5 A
2
0.25 T
2
1.09 cm2
104
= 0.44 mm
n1 =
LM IM,max
BmaxAc
104
=
1.07 ⋅ 10– 3
H 1.5 A
0.25 T 1.09 cm2
104
= 58.7 turns
n1 = 59Round to
n2 =
n2
n1
n1
= 0.15 59
= 8.81
n2 = 9
Fundamentals of Power Electronics Chapter 14: Inductor design59
Wire gauges
α1 =
I1
Itot
=
0.796 A
1.77 A
= 0.45
α2 =
n2I2
n1Itot
=
9 6.5 A
59 1.77 A
= 0.55
AW1 ≤
α1KuWA
n1
= 1.09 ⋅ 10– 3
cm2 — use #28 AWG
AW2 ≤
α2KuWA
n2
= 8.88 ⋅ 10– 3
cm2 — use #19 AWG
Fundamentals of Power Electronics Chapter 14: Inductor design60
Core loss
CCM flyback example
dB(t)
dt
=
vM (t)
n1Ac
dB(t)
dt
=
Vg
n1Ac
B(t)
Hc(t)
Minor B–H loop,
CCM flyback
example
B–H loop,
large excitation
Bsat
∆BBmax
vM(t)
0
Vg
DTs
B(t)
Bmax
0
∆B
Vg
n1Ac
B-H loop for this application: The relevant waveforms:
B(t) vs. applied voltage,
from Faraday’s law:
For the first
subinterval:
Fundamentals of Power Electronics Chapter 14: Inductor design61
Calculation of ac flux density
and core loss
Solve for B:
∆B =
Vg
n1Ac
DTs
Plug in values for flyback
example:
∆B =
200 V 0.4 6.67 µs
2 59 1.09 cm2
104
= 0.041 T
∆B, Tesla
0.01 0.1 0.3
Powerlossdensity,
Watts/cm3
0.01
0.1
1
20kHz
50kHz
100kHz
200kHz
400kHz
150kHz
0.04
W/cm3
0.041
From manufacturer’s plot of core
loss (at left), the power loss density
is 0.04 W/cm3. Hence core loss is
Pfe = 0.04 W/cm3 Ac lm
= 0.04 W/cm3 1.09 cm2 5.77 cm
= 0.25 W
Fundamentals of Power Electronics Chapter 14: Inductor design62
Comparison of core and copper loss
• Copper loss is 1.5 W
– does not include proximity losses, which could substantially increase
total copper loss
• Core loss is 0.25 W
– Core loss is small because ripple and B are small
– It is not a bad approximation to ignore core losses for ferrite in CCM
filter inductors
– Could consider use of a less expensive core material having higher
core loss
– Neglecting core loss is a reasonable approximation for this
application
• Design is dominated by copper loss
– The dominant constraint on flux density is saturation of the core,
rather than core loss
Fundamentals of Power Electronics Chapter 14: Inductor design63
14.5 Summary of key points
1. A variety of magnetic devices are commonly used in switching
converters. These devices differ in their core flux density
variations, as well as in the magnitudes of the ac winding
currents. When the flux density variations are small, core loss can
be neglected. Alternatively, a low-frequency material can be used,
having higher saturation flux density.
2. The core geometrical constant Kg is a measure of the magnetic
size of a core, for applications in which copper loss is dominant.
In the Kg design method, flux density and total copper loss are
specified.

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Chapter 14

  • 1. Fundamentals of Power Electronics Chapter 14: Inductor design1 Chapter 14 Inductor Design 14.1 Filter inductor design constraints 14.2 A step-by-step design procedure 14.3 Multiple-winding magnetics design using the Kg method 14.4 Examples 14.5 Summary of key points
  • 2. Fundamentals of Power Electronics Chapter 14: Inductor design2 14.1 Filter inductor design constraints Pcu = Irms 2 R Objective: Design inductor having a given inductance L, which carries worst-case current Imax without saturating, and which has a given winding resistance R, or, equivalently, exhibits a worst-case copper loss of L R i(t) + – L i(t) i(t) t0 DTs Ts I ∆iL Example: filter inductor in CCM buck converter
  • 3. Fundamentals of Power Electronics Chapter 14: Inductor design3 Assumed filter inductor geometry Solve magnetic circuit: Air gap reluctance Rg n turns i(t) Φ Core reluctance Rc + v(t) – + – ni(t) Φ(t) Rc Rg Fc + – Rc = lc µcAc Rg = lg µ0Ac ni = Φ Rc + Rg ni ≈ ΦRg Usually Rc < Rg and hence
  • 4. Fundamentals of Power Electronics Chapter 14: Inductor design4 14.1.1 Constraint: maximum flux density Given a peak winding current Imax, it is desired to operate the core flux density at a peak value Bmax. The value of Bmax is chosen to be less than the worst-case saturation flux density Bsat of the core material. From solution of magnetic circuit: Let I = Imax and B = Bmax : This is constraint #1. The turns ratio n and air gap length lg are unknown. ni = BAcRg nImax = Bmax Ac Rg = Bmax lg µ0
  • 5. Fundamentals of Power Electronics Chapter 14: Inductor design5 14.1.2 Constraint: inductance Must obtain specified inductance L. We know that the inductance is This is constraint #2. The turns ratio n, core area Ac, and air gap length lg are unknown. L = n2 Rg = µ0Ac n2 lg
  • 6. Fundamentals of Power Electronics Chapter 14: Inductor design6 14.1.3 Constraint: winding area core window area WA wire bare area AW core Wire must fit through core window (i.e., hole in center of core) nAW Total area of copper in window: KuWA Area available for winding conductors: Third design constraint: KuWA ≥ nAW
  • 7. Fundamentals of Power Electronics Chapter 14: Inductor design7 The window utilization factor Ku also called the “fill factor” Ku is the fraction of the core window area that is filled by copper Mechanisms that cause Ku to be less than 1: • Round wire does not pack perfectly, which reduces Ku by a factor of 0.7 to 0.55 depending on winding technique • Insulation reduces Ku by a factor of 0.95 to 0.65, depending on wire size and type of insulation • Bobbin uses some window area • Additional insulation may be required between windings Typical values of Ku : 0.5 for simple low-voltage inductor 0.25 to 0.3 for off-line transformer 0.05 to 0.2 for high-voltage transformer (multiple kV) 0.65 for low-voltage foil-winding inductor
  • 8. Fundamentals of Power Electronics Chapter 14: Inductor design8 14.1.4 Winding resistance The resistance of the winding is where is the resistivity of the conductor material, lb is the length of the wire, and AW is the wire bare area. The resistivity of copper at room temperature is 1.724 10–6 -cm. The length of the wire comprising an n-turn winding can be expressed as where (MLT) is the mean-length-per-turn of the winding. The mean- length-per-turn is a function of the core geometry. The above equations can be combined to obtain the fourth constraint: R = ρ n (MLT) AW R = ρ lb AW lb = n(MLT)
  • 9. Fundamentals of Power Electronics Chapter 14: Inductor design9 14.1.5 The core geometrical constant Kg The four constraints: R = ρ n (MLT) AW KuWA ≥ nAW These equations involve the quantities Ac, WA, and MLT, which are functions of the core geometry, Imax, Bmax , µ0, L, Ku, R, and , which are given specifications or other known quantities, and n, lg, and AW, which are unknowns. Eliminate the three unknowns, leading to a single equation involving the remaining quantities. nImax = Bmax Ac Rg = Bmax lg µ0 L = n2 Rg = µ0Ac n2 lg
  • 10. Fundamentals of Power Electronics Chapter 14: Inductor design10 Core geometrical constant Kg Ac 2 WA (MLT) ≥ ρL2 Imax 2 Bmax 2 RKu Elimination of n, lg, and AW leads to • Right-hand side: specifications or other known quantities • Left-hand side: function of only core geometry So we must choose a core whose geometry satisfies the above equation. The core geometrical constant Kg is defined as Kg = Ac 2 WA (MLT)
  • 11. Fundamentals of Power Electronics Chapter 14: Inductor design11 Discussion Kg = Ac 2 WA (MLT) ≥ ρL2 Imax 2 Bmax 2 RKu Kg is a figure-of-merit that describes the effective electrical size of magnetic cores, in applications where the following quantities are specified: • Copper loss • Maximum flux density How specifications affect the core size: A smaller core can be used by increasing Bmax use core material having higher Bsat R allow more copper loss How the core geometry affects electrical capabilities: A larger Kg can be obtained by increase of Ac more iron core material, or WA larger window and more copper
  • 12. Fundamentals of Power Electronics Chapter 14: Inductor design12 14.2 A step-by-step procedure The following quantities are specified, using the units noted: Wire resistivity ( -cm) Peak winding current Imax (A) Inductance L (H) Winding resistance R ( ) Winding fill factor Ku Core maximum flux density Bmax (T) The core dimensions are expressed in cm: Core cross-sectional area Ac (cm2) Core window area WA (cm2) Mean length per turn MLT (cm) The use of centimeters rather than meters requires that appropriate factors be added to the design equations.
  • 13. Fundamentals of Power Electronics Chapter 14: Inductor design13 Determine core size Kg ≥ ρL2 Imax 2 Bmax 2 RKu 108 (cm5 ) Choose a core which is large enough to satisfy this inequality (see Appendix D for magnetics design tables). Note the values of Ac, WA, and MLT for this core.
  • 14. Fundamentals of Power Electronics Chapter 14: Inductor design14 Determine air gap length with Ac expressed in cm2. µ0 = 4 10–7 H/m. The air gap length is given in meters. The value expressed above is approximate, and neglects fringing flux and other nonidealities. lg = µ0LImax 2 Bmax 2 Ac 104 (m)
  • 15. Fundamentals of Power Electronics Chapter 14: Inductor design15 AL Core manufacturers sell gapped cores. Rather than specifying the air gap length, the equivalent quantity AL is used. AL is equal to the inductance, in mH, obtained with a winding of 1000 turns. When AL is specified, it is the core manufacturer’s responsibility to obtain the correct gap length. The required AL is given by: AL = 10Bmax 2 Ac 2 LImax 2 (mH/1000 turns) L = AL n2 10– 9 (Henries) Units: Ac cm2, L Henries, Bmax Tesla.
  • 16. Fundamentals of Power Electronics Chapter 14: Inductor design16 Determine number of turns n n = LImax Bmax Ac 104
  • 17. Fundamentals of Power Electronics Chapter 14: Inductor design17 Evaluate wire size AW ≤ KuWA n (cm2 ) Select wire with bare copper area AW less than or equal to this value. An American Wire Gauge table is included in Appendix D. As a check, the winding resistance can be computed: R = ρn (MLT) Aw (Ω)
  • 18. Fundamentals of Power Electronics Chapter 14: Inductor design18 14.3 Multiple-winding magnetics design using the Kg method The Kg design method can be extended to multiple- winding magnetic elements such as transformers and coupled inductors. This method is applicable when – Copper loss dominates the total loss (i.e. core loss is ignored), or – The maximum flux density Bmax is a specification rather than a quantity to be optimized To do this, we must – Find how to allocate the window area between the windings – Generalize the step-by-step design procedure
  • 19. Fundamentals of Power Electronics Chapter 14: Inductor design19 14.3.1 Window area allocation n1 : n2 : nk rms current I1 rms current I2 rms current Ik v1(t) n1 = v2(t) n2 = = vk(t) nk Core Window area WA Core mean length per turn (MLT) Wire resistivity ρ Fill factor Ku Given: application with k windings having known rms currents and desired turns ratios Q: how should the window area WA be allocated among the windings?
  • 20. Fundamentals of Power Electronics Chapter 14: Inductor design20 Allocation of winding area Total window area WA Winding 1 allocation α1WA Winding 2 allocation α2 WA etc. { { 0 < αj < 1 α1 + α2 + + αk = 1
  • 21. Fundamentals of Power Electronics Chapter 14: Inductor design21 Copper loss in winding j Copper loss (not accounting for proximity loss) is Pcu,j = I j 2 Rj Resistance of winding j is with AW,j = WAKuαj nj length of wire, winding j wire area, winding j Hence Rj = ρ l j AW,j l j = nj (MLT) Rj = ρ n j 2 (MLT) WAKuα j Pcu,j = n j 2 i j 2 ρ(MLT) WAKuα j
  • 22. Fundamentals of Power Electronics Chapter 14: Inductor design22 Total copper loss of transformer Sum previous expression over all windings: Pcu,tot = Pcu,1 + Pcu,2 + + Pcu,k = ρ (MLT) WAKu nj 2 I j 2 αj Σj = 1 k Need to select values for 1, 2, …, k such that the total copper loss is minimized
  • 23. Fundamentals of Power Electronics Chapter 14: Inductor design23 Variation of copper losses with 1 For 1 = 0: wire of winding 1 has zero area. Pcu,1 tends to infinity For 1 = 1: wires of remaining windings have zero area. Their copper losses tend to infinity There is a choice of 1 that minimizes the total copper lossα1 Copper loss 0 1 Pcu,tot Pcu,1 P cu,2+ P cu,3+...+P cu,k
  • 24. Fundamentals of Power Electronics Chapter 14: Inductor design24 Method of Lagrange multipliers to minimize total copper loss Pcu,tot = Pcu,1 + Pcu,2 + + Pcu,k = ρ (MLT) WAKu nj 2 I j 2 αj Σj = 1 k subject to the constraint α1 + α2 + + αk = 1 Define the function f(α1, α2, , αk, ξ) = Pcu,tot(α1, α2, , αk) + ξ g(α1, α2, , αk) Minimize the function where g(α1, α2, , αk) = 1 – αjΣj = 1 k is the constraint that must equal zero and is the Lagrange multiplier
  • 25. Fundamentals of Power Electronics Chapter 14: Inductor design25 Lagrange multipliers continued Optimum point is solution of the system of equations ∂ f(α1, α2, , αk,ξ) ∂α1 = 0 ∂ f(α1, α2, , αk,ξ) ∂α2 = 0 ∂ f(α1, α2, , αk,ξ) ∂αk = 0 ∂ f(α1, α2, , αk,ξ) ∂ξ = 0 Result: ξ = ρ (MLT) WAKu njIjΣj = 1 k 2 = Pcu,tot αm = nmIm njIjΣn = 1 ∞ An alternate form: αm = VmIm VjIjΣn = 1 ∞
  • 26. Fundamentals of Power Electronics Chapter 14: Inductor design26 Interpretation of result αm = VmIm VjIjΣn = 1 ∞ Apparent power in winding j is Vj Ij where Vj is the rms or peak applied voltage Ij is the rms current Window area should be allocated according to the apparent powers of the windings
  • 27. Fundamentals of Power Electronics Chapter 14: Inductor design27 Ii1(t) n1 turns { }n2 turns }n2 turns i2(t) i3(t) Example PWM full-bridge transformer • Note that waveshapes (and hence rms values) of the primary and secondary currents are different • Treat as a three- winding transformer – n2 n1 I t i1(t) 0 0 n2 n1 I i2(t) I 0.5I 0.5I 0 i3(t) I 0.5I 0.5I 0 0 DTs Ts 2TsTs +DTs
  • 28. Fundamentals of Power Electronics Chapter 14: Inductor design28 Expressions for RMS winding currents I1 = 1 2Ts i1 2 (t)dt 0 2Ts = n2 n1 I D I2 = I3 = 1 2Ts i2 2 (t)dt 0 2Ts = 1 2 I 1 + D see Appendix A – n2 n1 I t i1(t) 0 0 n2 n1 I i2(t) I 0.5I 0.5I 0 i3(t) I 0.5I 0.5I 0 0 DTs Ts 2TsTs +DTs
  • 29. Fundamentals of Power Electronics Chapter 14: Inductor design29 Allocation of window area: αm = VmIm VjIjΣn = 1 ∞ α1 = 1 1 + 1 + D D α2 = α3 = 1 2 1 1 + D 1 + D Plug in rms current expressions. Result: Fraction of window area allocated to primary winding Fraction of window area allocated to each secondary winding
  • 30. Fundamentals of Power Electronics Chapter 14: Inductor design30 Numerical example Suppose that we decide to optimize the transformer design at the worst-case operating point D = 0.75. Then we obtain α1 = 0.396 α2 = 0.302 α3 = 0.302 The total copper loss is then given by Pcu,tot = ρ(MLT) WAKu njIjΣj = 1 3 2 = ρ(MLT)n2 2 I2 WAKu 1 + 2D + 2 D(1 + D)
  • 31. Fundamentals of Power Electronics Chapter 14: Inductor design31 14.3.2 Coupled inductor design constraints n1 : n2 : nk R1 R2 Rk + v1(t) – + v2(t) – + vk(t) – i1(t) i2(t) ik(t) LM iM(t) + –n1iM(t) Φ(t) Rc Rg Consider now the design of a coupled inductor having k windings. We want to obtain a specified value of magnetizing inductance, with specified turns ratios and total copper loss. Magnetic circuit model:
  • 32. Fundamentals of Power Electronics Chapter 14: Inductor design32 Relationship between magnetizing current and winding currents n1 : n2 : nk R1 R2 Rk + v1(t) – + v2(t) – + vk(t) – i1(t) i2(t) ik(t) LM iM(t) iM(t) = i1(t) + n2 n1 i2(t) + + nk n1 ik(t) Solution of circuit model, or by use of Ampere’s Law:
  • 33. Fundamentals of Power Electronics Chapter 14: Inductor design33 Solution of magnetic circuit model: Obtain desired maximum flux density + –n1iM(t) Φ(t) Rc Rg n1iM(t) = B(t)AcRg Assume that gap reluctance is much larger than core reluctance: Design so that the maximum flux density Bmax is equal to a specified value (that is less than the saturation flux density Bsat ). Bmax is related to the maximum magnetizing current according to n1IM,max = BmaxAcRg = Bmax lg µ0
  • 34. Fundamentals of Power Electronics Chapter 14: Inductor design34 Obtain specified magnetizing inductance LM = n1 2 Rg = n1 2 µ0 Ac lg By the usual methods, we can solve for the value of the magnetizing inductance LM (referred to the primary winding):
  • 35. Fundamentals of Power Electronics Chapter 14: Inductor design35 Copper loss Allocate window area as described in Section 14.3.1. As shown in that section, the total copper loss is then given by Pcu = ρ(MLT)n1 2 Itot 2 WAKu Itot = nj n1 I jΣj = 1 k with
  • 36. Fundamentals of Power Electronics Chapter 14: Inductor design36 Eliminate unknowns and solve for Kg Pcu = ρ(MLT)LM 2 Itot 2 IM,max 2 Bmax 2 Ac 2 WAKu Eliminate the unknowns lg and n1: Rearrange equation so that terms that involve core geometry are on RHS while specifications are on LHS: Ac 2 WA (MLT) = ρLM 2 Itot 2 IM,max 2 Bmax 2 KuPcu The left-hand side is the same Kg as in single-winding inductor design. Must select a core that satisfies Kg ≥ ρLM 2 Itot 2 IM,max 2 Bmax 2 KuPcu
  • 37. Fundamentals of Power Electronics Chapter 14: Inductor design37 14.3.3 Step-by-step design procedure: Coupled inductor The following quantities are specified, using the units noted: Wire resistivity ( -cm) Total rms winding currents (A) (referred to winding 1) Peak magnetizing current IM, max (A) (referred to winding 1) Desired turns ratios n2/n1. n3/n2. etc. Magnetizing inductance LM (H) (referred to winding 1) Allowed copper loss Pcu (W) Winding fill factor Ku Core maximum flux density Bmax (T) The core dimensions are expressed in cm: Core cross-sectional area Ac (cm2) Core window area WA (cm2) Mean length per turn MLT (cm) The use of centimeters rather than meters requires that appropriate factors be added to the design equations. Itot = nj n1 I jΣj = 1 k
  • 38. Fundamentals of Power Electronics Chapter 14: Inductor design38 1. Determine core size Kg ≥ ρLM 2 Itot 2 IM,max 2 Bmax 2 Pcu Ku 108 (cm5) Choose a core that satisfies this inequality. Note the values of Ac, WA, and MLT for this core. The resistivity of copper wire is 1.724 · 10–6 cm at room temperature, and 2.3 · 10–6 cm at 100˚C.
  • 39. Fundamentals of Power Electronics Chapter 14: Inductor design39 2. Determine air gap length lg = µ0LM IM,max 2 Bmax 2 Ac 104 (m) (value neglects fringing flux, and a longer gap may be required) The permeability of free space is µ0 = 4 · 10–7 H/m
  • 40. Fundamentals of Power Electronics Chapter 14: Inductor design40 3. Determine number of turns For winding 1: n1 = LM IM,max BmaxAc 104 For other windings, use the desired turns ratios: n2 = n2 n1 n1 n3 = n3 n1 n1
  • 41. Fundamentals of Power Electronics Chapter 14: Inductor design41 4. Evaluate fraction of window area allocated to each winding α1 = n1I1 n1Itot α2 = n2I2 n1Itot αk = nkIk n1Itot Total window area WA Winding 1 allocation α1WA Winding 2 allocation α2WA etc. { { 0 < αj < 1 α1 + α2 + + αk = 1
  • 42. Fundamentals of Power Electronics Chapter 14: Inductor design42 5. Evaluate wire sizes Aw1 ≤ α1KuWA n1 Aw2 ≤ α2KuWA n2 See American Wire Gauge (AWG) table at end of Appendix D.
  • 43. Fundamentals of Power Electronics Chapter 14: Inductor design43 14.4 Examples 14.4.1 Coupled Inductor for a Two-Output Forward Converter 14.4.2 CCM Flyback Transformer
  • 44. Fundamentals of Power Electronics Chapter 14: Inductor design44 14.4.1 Coupled Inductor for a Two-Output Forward Converter n1 + v1 – n2 turns i1 + v2 – i2 + –vg Output 1 28 V 4 A Output 2 12 V 2 Afs = 200 kHz The two filter inductors can share the same core because their applied voltage waveforms are proportional. Select turns ratio n2/n1 approximately equal to v2/v1 = 12/28.
  • 45. Fundamentals of Power Electronics Chapter 14: Inductor design45 Coupled inductor model and waveforms n1:n2 + v1 – i1 + v2 – i2 LM iM Coupled inductor model vM + – iM(t) vM(t) IM 0 0 – V1 ∆iM D′Ts Secondary-side circuit, with coupled inductor model Magnetizing current and voltage waveforms. iM(t) is the sum of the winding currents i1(t) + i2(t).
  • 46. Fundamentals of Power Electronics Chapter 14: Inductor design46 Nominal full-load operating point n1 + v1 – n2 turns i1 + v2 – i2 + –vg Output 1 28 V 4 A Output 2 12 V 2 Afs = 200 kHz Design for CCM operation with D = 0.35 iM = 20% of IM fs = 200 kHz DC component of magnetizing current is IM = I1 + n2 n1 I2 = (4 A) + 12 28 (2 A) = 4.86 A
  • 47. Fundamentals of Power Electronics Chapter 14: Inductor design47 Magnetizing current ripple iM(t) vM(t) IM 0 0 – V1 ∆iM D′Ts ∆iM = V1D′Ts 2LM To obtain iM = 20% of IM choose LM = V1D′Ts 2∆iM = (28 V)(1 – 0.35)(5 µs) 2(4.86 A)(20%) = 47 µH This leads to a peak magnetizing current (referred to winding 1) of IM,max = IM + ∆iM = 5.83 A
  • 48. Fundamentals of Power Electronics Chapter 14: Inductor design48 RMS winding currents Since the winding current ripples are small, the rms values of the winding currents are nearly equal to their dc comonents: I1 = 4 A I2 = 2 A Hence the sum of the rms winding currents, referred to the primary, is Itot = I1 + n2 n1 I2 = 4.86 A
  • 49. Fundamentals of Power Electronics Chapter 14: Inductor design49 Evaluate Kg The following engineering choices are made: – Allow 0.75 W of total copper loss (a small core having thermal resistance of less than 40 ˚C/W then would have a temperature rise of less than 30 ˚C) – Operate the core at Bmax = 0.25 T (which is less than the ferrite saturation flux density of 0.3 ot 0.5 T) – Use fill factor Ku = 0.4 (a reasonable estimate for a low- voltage inductor with multiple windings) Evaluate Kg: Kg ≥ (1.724 ⋅ 10– 6 Ω – cm)(47 µH)2 (4.86 A)2 (5.83 A)2 (0.25 T)2 (0.75 W)(0.4) 108 = 16 ⋅ 10– 3 cm5
  • 50. Fundamentals of Power Electronics Chapter 14: Inductor design50 Select core A1 2D It is decided to use a ferrite PQ core. From Appendix D, the smallest PQ core having Kg 16 · 10–3 cm5 is the PQ 20/16, with Kg = 22.4 · 10–3 cm5 . The data for this core are: Ac = 0.62 cm2 WA = 0.256 cm2 MLT = 4.4 cm
  • 51. Fundamentals of Power Electronics Chapter 14: Inductor design51 Air gap length lg = µ0LM IM,max 2 Bmax 2 Ac 104 = (4π ⋅ 10– 7 H/m)(47 µH)(5.83 A)2 (0.25 T)2 (0.62 cm2) 104 = 0.52 mm
  • 52. Fundamentals of Power Electronics Chapter 14: Inductor design52 Turns n1 = LM IM,max BmaxAc 104 = (47 µH)(5.83 A) (0.25 T)(0.62 cm2) 104 = 17.6 turns n2 = n2 n1 n1 = 12 28 (17.6) = 7.54 turns Let’s round off to n1 = 17 n2 = 7
  • 53. Fundamentals of Power Electronics Chapter 14: Inductor design53 Wire sizes Allocation of window area: α1 = n1I1 n1Itot = (17)(4 A) (17)(4.86 A) = 0.8235 α2 = n2I2 n1Itot = (7)(2 A) (17)(4.86 A) = 0.1695 Aw1 ≤ α1KuWA n1 = (0.8235)(0.4)(0.256cm2) (17) = 4.96 ⋅ 10– 3 cm2 use AWG #21 Aw2 ≤ α2KuWA n2 = (0.1695)(0.4)(0.256cm2) (7) = 2.48 ⋅ 10– 3 cm2 use AWG #24 Determination of wire areas and AWG (from table at end of Appendix D):
  • 54. Fundamentals of Power Electronics Chapter 14: Inductor design54 14.4.2 Example 2: CCM flyback transformer + – LM + V – Vg Q1 D1 n1 : n2 C Transformer model iM i1 R + vM – i2 vM(t) 0 Vg DTs iM(t) IM 0 ∆iM i1(t) IM 0 i2(t) IM 0 n1 n2
  • 55. Fundamentals of Power Electronics Chapter 14: Inductor design55 Specifications Input voltage Vg = 200V Output (full load) 20 V at 5 A Switching frequency 150 kHz Magnetizing current ripple 20% of dc magnetizing current Duty cycle D = 0.4 Turns ratio n2/n1 = 0.15 Copper loss 1.5 W Fill factor Ku = 0.3 Maximum flux density Bmax = 0.25 T
  • 56. Fundamentals of Power Electronics Chapter 14: Inductor design56 Basic converter calculations IM = n2 n1 1 D′ V R = 1.25 A ∆iM = 20% IM = 0.25 A IM,max = IM + ∆iM = 1.5 A Components of magnetizing current, referred to primary: Choose magnetizing inductance: LM = Vg DTs 2∆iM = 1.07 mH RMS winding currents: I1 = IM D 1 + 1 3 ∆iM IM 2 = 0.796 A I2 = n1 n2 IM D′ 1 + 1 3 ∆iM IM 2 = 6.50 A Itot = I1 + n2 n1 I2 = 1.77 A
  • 57. Fundamentals of Power Electronics Chapter 14: Inductor design57 Choose core size Kg ≥ ρLM 2 Itot 2 IM,max 2 Bmax 2 Pcu Ku 108 = 1.724 ⋅ 10– 6 Ω-cm 1.07 ⋅ 10– 3 H 2 1.77 A 2 1.5 A 2 0.25 T 2 1.5 W 0.3 108 = 0.049 cm5 The smallest EE core that satisfies this inequality (Appendix D) is the EE30. A
  • 58. Fundamentals of Power Electronics Chapter 14: Inductor design58 Choose air gap and turns lg = µ0LM IM,max 2 Bmax 2 Ac 104 = 4π ⋅ 10– 7 H/m 1.07 ⋅ 10– 3 H 1.5 A 2 0.25 T 2 1.09 cm2 104 = 0.44 mm n1 = LM IM,max BmaxAc 104 = 1.07 ⋅ 10– 3 H 1.5 A 0.25 T 1.09 cm2 104 = 58.7 turns n1 = 59Round to n2 = n2 n1 n1 = 0.15 59 = 8.81 n2 = 9
  • 59. Fundamentals of Power Electronics Chapter 14: Inductor design59 Wire gauges α1 = I1 Itot = 0.796 A 1.77 A = 0.45 α2 = n2I2 n1Itot = 9 6.5 A 59 1.77 A = 0.55 AW1 ≤ α1KuWA n1 = 1.09 ⋅ 10– 3 cm2 — use #28 AWG AW2 ≤ α2KuWA n2 = 8.88 ⋅ 10– 3 cm2 — use #19 AWG
  • 60. Fundamentals of Power Electronics Chapter 14: Inductor design60 Core loss CCM flyback example dB(t) dt = vM (t) n1Ac dB(t) dt = Vg n1Ac B(t) Hc(t) Minor B–H loop, CCM flyback example B–H loop, large excitation Bsat ∆BBmax vM(t) 0 Vg DTs B(t) Bmax 0 ∆B Vg n1Ac B-H loop for this application: The relevant waveforms: B(t) vs. applied voltage, from Faraday’s law: For the first subinterval:
  • 61. Fundamentals of Power Electronics Chapter 14: Inductor design61 Calculation of ac flux density and core loss Solve for B: ∆B = Vg n1Ac DTs Plug in values for flyback example: ∆B = 200 V 0.4 6.67 µs 2 59 1.09 cm2 104 = 0.041 T ∆B, Tesla 0.01 0.1 0.3 Powerlossdensity, Watts/cm3 0.01 0.1 1 20kHz 50kHz 100kHz 200kHz 400kHz 150kHz 0.04 W/cm3 0.041 From manufacturer’s plot of core loss (at left), the power loss density is 0.04 W/cm3. Hence core loss is Pfe = 0.04 W/cm3 Ac lm = 0.04 W/cm3 1.09 cm2 5.77 cm = 0.25 W
  • 62. Fundamentals of Power Electronics Chapter 14: Inductor design62 Comparison of core and copper loss • Copper loss is 1.5 W – does not include proximity losses, which could substantially increase total copper loss • Core loss is 0.25 W – Core loss is small because ripple and B are small – It is not a bad approximation to ignore core losses for ferrite in CCM filter inductors – Could consider use of a less expensive core material having higher core loss – Neglecting core loss is a reasonable approximation for this application • Design is dominated by copper loss – The dominant constraint on flux density is saturation of the core, rather than core loss
  • 63. Fundamentals of Power Electronics Chapter 14: Inductor design63 14.5 Summary of key points 1. A variety of magnetic devices are commonly used in switching converters. These devices differ in their core flux density variations, as well as in the magnitudes of the ac winding currents. When the flux density variations are small, core loss can be neglected. Alternatively, a low-frequency material can be used, having higher saturation flux density. 2. The core geometrical constant Kg is a measure of the magnetic size of a core, for applications in which copper loss is dominant. In the Kg design method, flux density and total copper loss are specified.