CH 15 Slides

Chapter 15 Transformer Design
Some more advanced design issues, not considered in previous chapter: n1 : n2 Inclusion of core loss + + i1(t) Selection of operating flux v2(t) v1(t) density to optimize total loss Multiple winding design: as in the coupled-inductor case, allocate the available window area among several windings A transformer design procedure How switching frequency affects transformer size
1
i2(t)
R1
R2 + vk(t) : nk Rk ik (t)
Fundamentals of Power Electronics
Chapter 15: Transformer design
Chapter 15 Transformer Design
15.1 15.2 15.3 15.4 15.5
Transformer design: Basic constraints A step-by-step transformer design procedure Examples AC inductor design Summary
15.1 Transformer Design:

Basic Constraints
Core loss
P fe = K fe(B) A c l m
Typical value of for ferrite materials: 2.6 or 2.7 B is the peak value of the ac component of B(t), i.e., the peak ac flux density So increasing B causes core loss to increase rapidly This is the first constraint
Flux density
Constraint #2
Flux density B(t) is related to the applied winding voltage according to Faradays Law. Denote the voltseconds applied to the primary winding during the positive portion of v1(t) as 1:
t2
v1(t) area 1
t1
t2
1 =
t1
v1(t)dt
This causes the flux to change from its negative peak to its positive peak. From Faradays law, the peak value of the ac component of flux density is
To attain a given flux density, the primary turns should be chosen according to
B =
1 2n 1A c
4
n1 =
1 2BA c
Copper loss
Constraint #3
Allocate window area between windings in optimum manner, as described in previous section Total copper loss is then equal to
2 2 1 tot
with
Pcu =
(MLT)n I WAK u
I tot =
j=1
nj n1 I j
Eliminate n1, using result of previous slide:
2 I 2 1 tot Pcu = 4K u
(MLT ) WA A2 c
1 B
Note that copper loss decreases rapidly as B is increased
Total power loss

4. Ptot = Pcu + Pfe
There is a value of B that minimizes the total power loss
Power loss
ss P Co re l o
Co ppe r lo ss P c
Ptot
Ptot = Pfe + Pcu
Optimum B B
(MLT ) WA A2 c
1 B
6
fe
5. Find optimum flux density B

Given that
Ptot = Pfe + Pcu

Then, at the B that minimizes Ptot, we can write
dP fe dPcu dPtot = + =0 d(B) d(B) d(B)

Note: optimum does not necessarily occur where Pfe = Pcu. Rather, it occurs where
dP fe dPcu = d(B) d(B)
Take derivatives of core and copper loss

(MLT ) WA A2 c
1 B
dP fe = K fe (B) d(B)
Aclm
2 I 2 dPcu 1 tot =2 d(B) 4K u
(MLT) (B) 3 WA A2 c
Now, substitute into
dP fe dPcu = d(B) d(B)

1 +2
and solve for B:
B =
2 I 2 1 tot 2K u
(MLT ) 1 3 W A A c l m K fe
Optimum B for a given core and application
Total loss
Substitute optimum B into expressions for Pcu and Pfe. The total loss is:
+2
Ptot = A c l m K fe
2 +2
2 I 2 1 tot 4K u
(MLT ) WA A2 c
+2
2 +2
Rearrange as follows:
WA Ac
2( 1)/
2/ (MLT )l m
+2
2 +2
+2
2 I 2 K fe 1 tot 4K u Ptot
2/
+ 2 /
Left side: terms depend on core geometry
Right side: terms depend on specifications of the application
The core geometrical constant Kgfe

Define
K gfe =
WA Ac
2( 1)/
2/ (MLT)l m
+2
2 +2
+2
Design procedure: select a core that satisfies
K gfe
2/
+ 2 /
Appendix D lists the values of Kgfe for common ferrite cores Kgfe is similar to the Kg geometrical constant used in Chapter 14: Kg is used when Bmax is specified Kgfe is used when B is to be chosen to minimize total loss
10
15.2 Step-by-step transformer design procedure

The following quantities are specified, using the units noted: Wire effective resistivity ( -cm) Total rms winding current, ref to pri Itot (A) Desired turns ratios n2/n1, n3/n1, etc. Applied pri volt-sec (V-sec) 1 (W) Allowed total power dissipation Ptot Winding fill factor Ku Core loss exponent Core loss coefficient Kfe (W/cm3T ) Other quantities and their dimensions: Core cross-sectional area Ac Core window area WA Mean length per turn MLT Magnetic path length le Wire areas Aw1, Peak ac flux density B
11
(cm2) (cm2) (cm) (cm) (cm2) (T)

Procedure
1. Determine core size
2/
K gfe
+ 2 /
10 8
Select a core from Appendix D that satisfies this inequality. It may be possible to reduce the core size by choosing a core material that has lower loss, i.e., lower Kfe.
12
2.
Evaluate peak ac flux density

1 +2
2 I 2 (MLT ) 1 tot 1 B = 10 2K u W A A 3 l m K fe c
8
At this point, one should check whether the saturation flux density is exceeded. If the core operates with a flux dc bias Bdc, then B + Bdc should be less than the saturation flux density Bsat. If the core will saturate, then there are two choices: Specify B using the Kg method of Chapter 14, or Choose a core material having greater core loss, then repeat steps 1 and 2
13
3. and 4.
Primary turns:
Evaluate turns
n1 =
1 10 4 2BA c
Choose secondary turns according to desired turns ratios:
n2 = n1 n3 = n1
n2 n1 n3 n1
14
5. and 6.
Fraction of window area assigned to each winding:
Choose wire sizes

Choose wire sizes according to:
n 1I 1 1 = n 1I tot n 2I 2 2 = n 1I tot n kI k k = n 1I tot
1K uWA n1 2K uWA A w2 n2 A w1
15
Check: computed transformer model

Predicted magnetizing inductance, referred to primary:
n1 : n2 i1(t) iM (t) LM R1 R2 ik(t) i2(t)
n 2 A c LM = 1 lm
Peak magnetizing current:
1 i M, pk = 2L M
Predicted winding resistances:
n 1(MLT) A w1 n (MLT) R2 = 2 A w2 R1 =
: nk
Rk
16
15.4.1
Ig
4A
Example 1: Single-output isolated Cuk converter

+ vC1(t) vC2(t) + + v2(t) i1(t) n:1 i2(t) V
5V
I
20 A
Vg
25 V
v1(t) +
100 W D = 0.5 Ku = 0.5
fs = 200 kHz n=5 Allow Ptot = 0.25 W
Use a ferrite pot core, with Magnetics Inc. P material. Loss parameters at 200 kHz are Kfe = 24.7
= 2.6
17
Waveforms
v1(t) VC1 Area 1
D'Ts DTs
Applied primary voltseconds:

nVC2
1 = DTsVc1 = (0.5) (5 sec ) (25 V) = 62.5 Vsec
i1(t)
I/n
Applied primary rms current:

I1 =
Ig
I D n
+ D' I g
=4A
i2(t)
Applied secondary rms current: I 2 = nI 1 = 20 A Total rms winding current: I tot = I 1 + 1 I 2 = 8 A n

18
nIg
Choose core size

(1.72410 6)(62.510 6) 2(8) 2(24.7) 2/2.6 K gfe 10 8 4 (0.5) (0.25) 4.6/2.6 = 0.00295
Pot core data of Appendix D lists 2213 pot core with Kgfe = 0.0049 Next smaller pot core is not large enough.
19
Evaluate peak ac flux density

1/4.6
(1.72410 6 )(62.510 6 ) 2(8) 2 (4.42) 1 B = 10 3 2 (0.5) (0.297)(0.635) (3.15) (2.6)(24.7)

8
= 0.0858 Tesla
This is much less than the saturation flux density of approximately 0.35 T. Values of B in the vicinity of 0.1 T are typical for ferrite designs that operate at frequencies in the vicinity of 100 kHz.
20
Evaluate turns
(62.510 6) n 1 = 10 4 2(0.0858)(0.635) = 5.74 turns
n1 n 2 = n = 1.15 turns
In practice, we might select n1 = 5 and n2 = 1
This would lead to a slightly higher flux density and slightly higher loss.
21
Determine wire sizes

Fraction of window area allocated to each winding:
1 = 2 =
4A 8A
1 5
= 0.5 = 0.5
20 A 8A
(Since, in this example, the ratio of winding rms currents is equal to the turns ratio, equal areas are allocated to each winding) From wire table, Appendix D: AWG #16 AWG #9
Wire areas:
(0.5)(0.5)(0.297) = 14.810 3 cm 2 (5) (0.5)(0.5)(0.297) A w2 = = 74.210 3 cm 2 (1) A w1 =
22
Wire sizes: discussion

Primary
5 turns #16 AWG
Secondary
1 turn #9 AWG
Very large conductors! One turn of #9 AWG is not a practical solution
Some alternatives
Use foil windings Use Litz wire or parallel strands of wire
23
Effect of switching frequency on transformer size

for this P-material Cuk converter example
4226 3622 0.1 0.08 0.06 0.04 0.02 0 25 kHz 50 kHz 100 kHz 200 kHz 250 kHz 400 kHz 500 kHz 1000 kHz
Pot core size
Bmax , Tesla
2616 2213 1811 1811 2213
2616
Switching frequency
As switching frequency is increased from 25 kHz to 250 kHz, core size is dramatically reduced
24
As switching frequency is increased from 400 kHz to 1 MHz, core size increases
15.3.2
Q1
Example 2
Multiple-Output Full-Bridge Buck Converter
D1 Q3 D3
T1 n1 : +
: n2 D5
I5V i2a(t)
100 A
+ 5V
Vg
160 V
i1(t) v1(t)
D2 D4 : n2 : n3 D7 D6
i2b(t) I15V i3a(t)

15 A
Q2
Q4
+ 15 V
Switching frequency Transformer frequency Turns ratio Optimize transformer at
150 kHz 75 kHz 110:5:15 D = 0.75

: n3 D8
i2b(t)
25
Other transformer design details

Use Magnetics, Inc. ferrite P material. Loss parameters at 75 kHz: Kfe = 7.6 W/T cm3 = 2.6 Use E-E core shape Assume fill factor of Ku = 0.25 (reduced fill factor accounts for added insulation required in multiple-output off-line application)
Allow transformer total power loss of Ptot = 4 W = 1.724106 (approximately 0.5% of total output power)
Use copper wire, with -cm

26
Applied transformer waveforms

D3
T1 n1 : +
: n2 D5
v1(t)
Vg
i2a(t)
Area 1 = Vg DTs 0 Vg 0
i1(t) v (t) 1
D4 : n2 : n3 D7 D6
i1(t)
n n2 I 5V + 3 I 15V n1 n1
i2b(t)
0
i3a(t)
i2a(t)
n n2 I 5V + 3 I 15V n1 n1
I5V 0.5I5V 0
D8 : n3
i2b(t)
i3a(t)
I15V 0.5I15V 0
0 DTs Ts Ts+DTs 2Ts
27
Applied primary volt-seconds

v1(t) Vg Area 1 = Vg DTs 0 Vg 0
1 = DTsVg = (0.75) (6.67 sec ) (160 V) = 800 Vsec
28
Applied primary rms current

i1(t)
n n2 I 5V + 3 I 15V n1 n1
0
n n2 I 5V + 3 I 15V n1 n1
n2 n3 I 1 = n I 5V + n I 15V 1 1
D = 5.7 A
29
Applied rms current, secondary windings

i2a(t) I5V 0.5I5V 0 i3a(t) I15V 0.5I15V 0
0 DTs Ts Ts+DTs 2Ts
I 2 = 1 I 5V 1 + D = 66.1 A 2
I 3 = 1 I 15V 1 + D = 9.9 A 2
30
Itot
RMS currents, summed over all windings and referred to primary
I tot =
all 5 windings
nj n2 n3 n1 I j = I 1 + 2 n1 I 2 + 2 n1 I 3
= 5.7 A + 5 66.1 A + 15 9.9 A 110 110 = 14.4 A
31
Select core size

(1.72410 6)(80010 6) 2(14.4) 2(7.6) 2/2.6 K gfe 10 8 4 (0.25) (4) 4.6/2.6 = 0.00937
From Appendix D
32
Evaluate ac flux density B

1 +2
Eq. (15.20):
2I 2 (MLT) 1 1 tot Bmax = 10 8 2K u WAA 3l m K fe c
Plug in values:
1/4.6
(1.72410 6 )(80010 6 ) 2(14.4) 2 (8.5) 1 B = 10 3 2(0.25) (1.1)(1.27) (7.7) (2.6)(7.6)

8
= 0.23 Tesla
This is less than the saturation flux density of approximately 0.35 T
33
Evaluate turns
Choose n1 according to Eq. (15.21):
n1 =
1 10 4 2BA c
4
Rounding the number of turns

To obtain desired turns ratio of 110:5:15 we might round the actual turns to 22:1:3 Increased n1 would lead to Less core loss More copper loss Increased total loss
(80010 6) n 1 = 10 2(0.23)(1.27) = 13.7 turns

Choose secondary turns according to desired turns ratios:
5 n2 = n = 0.62 turns 110 1 15 n = 1.87 turns n3 = 110 1

34
Loss calculation
with rounded turns
With n1 = 22, the flux density will be reduced to
(80010 6 ) B = 10 4 = 0.143 Tesla 2(22)(1.27)

The resulting losses will be
Pfe = (7.6)(0.143) 2.6(1.27)(7.7) = 0.47 W

(8.5) (1.72410 6)(80010 6) 2(14.4) 2 1 Pcu = 10 8 4 (0.25) (1.1)(1.27) 2 (0.143) 2 = 5.4 W
Ptot = Pfe + Pcu = 5.9 W
Which exceeds design goal of 4 W by 50%. So use next larger core size: EE50.
35
Calculations with EE50

Repeat previous calculations for EE50 core size. Results: B = 0.14 T, n1 = 12, Ptot = 2.3 W Again round n1 to 22. Then B = 0.08 T, Pcu = 3.89 W, Pfe = 0.23 W, Ptot = 4.12 W Which is close enough to 4 W.
36
Wire sizes for EE50 design

Window allocations Wire gauges
1K uWA (0.396)(0.25)(1.78) = = 8.010 3 cm 2 (22) n1 AWG #19 KW (0.209)(0.25)(1.78) = 93.010 3 cm 2 A w2 = 2 u A = (1) n2 A w1 = AWG #8 KW (0.094)(0.25)(1.78) = 13.910 3 cm 2 A w3 = 3 u A = (3) n3 AWG #16
1 =
I1 = 5.7 = 0.396 I tot 14.4

n 2I 2 = 5 66.1 = 0.209 n 1I tot 110 14.4
2 =
3 =
n 3I 3 = 15 9.9 = 0.094 n 1I tot 110 14.4
Might actually use foil or Litz wire for secondary windings
37
Discussion: Transformer design

Process is iterative because of round-off of physical number of turns and, to a lesser extent, other quantities Effect of proximity loss
Not included in design process yet Requires additional iterations
Can modify procedure as follows:

After a design has been calculated, determine number of layers in each winding and then compute proximity loss Alter effective resistivity of wire to compensate: define
eff
= Pcu/Pdc where Pcu is the total copper loss (including proximity effects) and Pdc is the copper loss predicted by the dc resistance.
Apply transformer design procedure using this effective wire resistivity, and compute proximity loss in the resulting design. Further iterations may be necessary if the specifications are not met.
38
15.4 AC Inductor Design

i(t) + v(t)
v(t) Area
Window area WA Core mean length per turn (MLT )
Core Core area Ac Air gap lg
n turns Wire resistivity Fill factor Ku

t
t1
t2
i(t)
Design a single-winding inductor, having an air gap, accounting for core loss
(note that the previous design procedure of this chapter did not employ an air gap, and inductance was not a specification)
39
Outline of key equations

Obtain specified inductance: Total loss is minimized when
0 Acn2 L= lg
Relationship between applied volt-seconds and peak ac flux density:
B =
I 2K u
2 2
(MLT ) 1 3 W A A c l m K fe
1 +2
Must select core that satisfies
B =
2nA c
K gfe
2I 2K fe 2K u Ptot
2/
+ 2 /
Copper loss (using dc resistance):
n 2(MLT ) 2 Pcu = I K uW A
40
See Section 15.4.2 for step-by-step design equations

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Chapter 15 Transformer Design

Fundamentals of Power Electronics

Chapter 15: Transformer design

Chapter 15 Transformer Design

15.1 15.2 15.3 15.4 15.5

Fundamentals of Power Electronics

Chapter 15: Transformer design

15.1 Transformer Design:

Fundamentals of Power Electronics

Chapter 15: Transformer design

Fundamentals of Power Electronics

Chapter 15: Transformer design

Eliminate n1, using result of previous slide:

Note that copper loss decreases rapidly as B is increased

Fundamentals of Power Electronics

Chapter 15: Transformer design

Total power loss

Ptot = Pfe + Pcu

Chapter 15: Transformer design

5. Find optimum flux density B

Ptot = Pfe + Pcu

dP fe dPcu dPtot = + =0 d(B) d(B) d(B)

dP fe dPcu = d(B) d(B)

Fundamentals of Power Electronics

Chapter 15: Transformer design

Take derivatives of core and copper loss

2 I 2 dPcu 1 tot =2 d(B) 4K u

Now, substitute into

dP fe dPcu = d(B) d(B)

and solve for B:

Optimum B for a given core and application

Fundamentals of Power Electronics

Chapter 15: Transformer design

Left side: terms depend on core geometry

Right side: terms depend on specifications of the application

Fundamentals of Power Electronics

Chapter 15: Transformer design

The core geometrical constant Kgfe

Design procedure: select a core that satisfies

Fundamentals of Power Electronics

Chapter 15: Transformer design

15.2 Step-by-step transformer design procedure

(cm2) (cm2) (cm) (cm) (cm2) (T)

Fundamentals of Power Electronics

Chapter 15: Transformer design

Evaluate peak ac flux density

Fundamentals of Power Electronics

Chapter 15: Transformer design

Choose secondary turns according to desired turns ratios:

Fundamentals of Power Electronics

Chapter 15: Transformer design

Choose wire sizes

n 1I 1 1 = n 1I tot n 2I 2 2 = n 1I tot n kI k k = n 1I tot

Fundamentals of Power Electronics

Chapter 15: Transformer design

Check: computed transformer model

n1 : n2 i1(t) iM (t) LM R1 R2 ik(t) i2(t)

Fundamentals of Power Electronics

Chapter 15: Transformer design

Example 1: Single-output isolated Cuk converter

100 W D = 0.5 Ku = 0.5

fs = 200 kHz n=5 Allow Ptot = 0.25 W

Chapter 15: Transformer design