Null 9

Power Electronics
EE410
Dr. T. Marisa <tmarisa@uz.ac.zw>
Department of Electrical Engineering

University of Zimbabwe
Outline
Magnetics
Design and
Physical
Construction
1 Magnetics Design and Physical Construction

Inductors Design
Transformer Design
EE410 Dept. of Electrical Engineering -2- T. Marisa | tmarisa@uz.ac.zw

Outline
Magnetics
Design and
Physical
Construction
Inductors Design
Transformer Design
1 Magnetics Design and Physical Construction

Inductors Design
Transformer Design

Magnetics Design and Physical
Construction
Magnetics
Design and
Physical How are inductors constructed?
Construction
Inductors Design
Transformer Design
Can we link the construction to conservation of space,
matter and energy?
Linking these three constrains allows us to consider
physical construction in our mathematical models.
For example we have limited space to put our windings,
therefore for optimal design we also need to model this
constraint and relate it to our electrical and magnetic
constraints.

Construction
Magnetics
Design and
Construction
Inductors Design
Transformer Design
matter and energy?
constraints.

Construction
Magnetics
Design and
Construction
Inductors Design
Transformer Design
matter and energy?
constraints.

Construction
Magnetics
Design and
Construction
Inductors Design
Transformer Design
matter and energy?
constraints.

Construction
Wire must fit through core window (i.e., hole in center of
Magnetics core).
Design and
Physical
Construction In addition to electrical and
Inductors Design
Transformer Design
magnetic constraints we also
have space constraints.
Figure: Cross-sections of typical planar and deep-diffused diode

junctions.

Construction
Magnetics core).
Design and
Physical
Construction core
Inductors Design
Transformer Design wire bare area
Total area of AW
copper in window:
nA W core window
area WA
Area available for winding
conductors:
K uW A
In addition to electrical and
Third design constraint:
K uWA ≥ nA W magnetic constraints we also

junctions.

Construction
Magnetics core).
Design and
Physical
Construction core
Inductors Design
Transformer Design wire bare area
Total area of AW
copper in window:
nA W core window
area WA
Area available for winding
conductors:
K uW A
In addition to electrical and
Third design constraint:
K uWA ≥ nA W magnetic constraints we also

junctions.

The window utilization factor Ku
The window utilization factor Ku is also called the “fill
factor”.
Magnetics
Design and Ku is the fraction of the core window area that is filled
Physical
Construction by copper
Inductors Design
Transformer Design
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
factor”.
Magnetics
Physical
Inductors Design
Transformer Design
technique
factor”.
Magnetics
Physical
Inductors Design
Transformer Design
technique
factor”.
Magnetics
Physical
Inductors Design
Transformer Design
technique
factor”.
Magnetics
Physical
Inductors Design
Transformer Design
technique
factor”.
Magnetics
Physical
Inductors Design
Transformer Design
technique
factor”.
Magnetics
Physical
Inductors Design
Transformer Design
technique
factor”.
Magnetics
Physical
Inductors Design
Transformer Design
technique
factor”.
Magnetics
Physical
Inductors Design
Transformer Design
technique
factor”.
Magnetics
Physical
Inductors Design
Transformer Design
technique
factor”.
Magnetics
Physical
Inductors Design
Transformer Design
technique
factor”.
Magnetics
Physical
Inductors Design
Transformer Design
technique
Winding Resistance ⇒ To Turns
ℓb ρ
The DC resistance of a wire is: R =
Aw
Magnetics
where Aw is the cross-sectional area of the wire (wire
Design and
Physical
bare area) and ℓb is the length of the wire, and ρ is the
Construction
Inductors Design
resistivity of the conductor material.
Transformer Design The resistivity of copper ρ at room temperature is
1.724 × 10−6 Ω cm−1 .
The length of the wire comprising an n-turn winding can
be expressed as
ℓb = n · MLT
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: n · MLT · ρ
R=
Aw
ℓb ρ
Aw
Magnetics
Design and
Physical
Construction
Inductors Design
1.724 × 10−6 Ω cm−1 .
be expressed as
ℓb = n · MLT
geometry.
R=
Aw
ℓb ρ
Aw
Magnetics
Design and
Physical
Construction
Inductors Design
1.724 × 10−6 Ω cm−1 .
be expressed as
ℓb = n · MLT
geometry.
R=
Aw
ℓb ρ
Aw
Magnetics
Design and
Physical
Construction
Inductors Design
1.724 × 10−6 Ω cm−1 .
be expressed as
ℓb = n · MLT
geometry.
R=
Aw
ℓb ρ
Aw
Magnetics
Design and
Physical
Construction
Inductors Design
1.724 × 10−6 Ω cm−1 .
be expressed as
ℓb = n · MLT
geometry.
R=
Aw
Winding and Geometry
Our design constraints are:

The four constraints:
2 µ A n2
Magnetics
nI max = Bmax A c R g = Bmax
lg L= n = 0 c
Design and µ0 Rg lg
Physical
Construction
Inductors Design
K uWA ≥ nA W n (MLT)
Transformer Design R=ρ
AW
These equations involve the quantities Ac , WA , and
MLT, which are functions of the core geometry,
Imax , Bmax , µ0 , L, Ku , R, and ρ, which are given
specifications (electrical and magnetic) or other known
quantities, and
n, ℓg , and AW , which are the unknowns we need to find.
Eliminate the three unknowns, leading to a single
equation involving the remaining quantities.


2 µ A n2
Magnetics
lg L= n = 0 c
Physical
Construction
Inductors Design
AW
quantities, and


2 µ A n2
Magnetics
lg L= n = 0 c
Physical
Construction
Inductors Design
AW
quantities, and


2 µ A n2
Magnetics
lg L= n = 0 c
Physical
Construction
Inductors Design
AW
quantities, and


2 µ A n2
Magnetics
lg L= n = 0 c
Physical
Construction
Inductors Design
AW
quantities, and

Elimination of n, ℓg , and AW leads to

A 2c WA ρL 2I 2max
Magnetics
≥
Design and
Physical
(MLT) B 2max RK u
Construction
Inductors Design
Transformer Design
• 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


A 2c WA ρL 2I 2max
Magnetics
≥
Design and
Physical
(MLT) B 2max RK u
Construction
Inductors Design
Transformer Design
quantities
the above equation.


A 2c WA ρL 2I 2max
Magnetics
≥
Design and
Physical
(MLT) B 2max RK u
Construction
Inductors Design
Transformer Design
quantities
the above equation.


A 2c WA ρL 2I 2max
Magnetics
≥
Design and
Physical
(MLT) B 2max RK u
Construction
Inductors Design
Transformer Design
quantities
the above equation.


A 2c WA ρL 2I 2max
Magnetics
≥ 2ρ
Design and
Physical
(MLT) ≥ B max RK u
Construction
Inductors Design
Transformer Design
quantities
the above equation.
A 2c WA
Kg =
(MLT)

The core geometrical constant Kg is related to the other
constraints as
Magnetics A 2c WA ρL 2I 2
Design and Kg = ≥ 2 max
Physical
Construction
(MLT) B max RK u
Inductors Design
Transformer Design 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
EE410 Dept. of Electrical Engineering - 10 - T. Marisa | tmarisa@uz.ac.zw
constraints as
Physical
Construction
(MLT) B max RK u
Inductors Design
• Copper loss
can be used
by increasing

constraints as
Physical
Construction
(MLT) B max RK u
Inductors Design
• Copper loss
can be used
by increasing

constraints as
Physical
Construction
(MLT) B max RK u
Inductors Design
• Copper loss
can be used
by increasing

constraints as
Physical
Construction
(MLT) B max RK u
Inductors Design
• Copper loss
can be used
by increasing

constraints as
Physical
Construction
(MLT) B max RK u
Inductors Design
• Copper loss
can be used
by increasing

constraints as
Physical
Construction
(MLT) B max RK u
Inductors Design
• Copper loss
can be used
by increasing

constraints as
Physical
Construction
(MLT) B max RK u
Inductors Design
• Copper loss
can be used
by increasing

constraints as
Physical
Construction
(MLT) B max RK u
Inductors Design
• Copper loss
can be used
by increasing

constraints as
Physical
Construction
(MLT) B max RK u
Inductors Design
• Copper loss
can be used
by increasing

constraints as
Physical
Construction
(MLT) B max RK u
Inductors Design
• Copper loss
can be used
by increasing

Winding and Geometry: Variables
The following quantities are specified, using the units

noted:
Magnetics
Design and Wire resistivity (-cm)
Physical
Construction
Peak winding current Imax (A)
Inductors Design
Transformer Design
Inductance L (H)
Winding resistance R ()
Winding fill factor Ku
Core maximum flux density Bmax (T)
The core dimensions are expressed in cm:
The use of centimeters rather than meters requires that

appropriate factors be added to the design equations.


noted:
Magnetics
Design and Wire resistivity
(-cm)
Physical
Construction
Inductors Design
Transformer Design
Inductance L (H)
Winding resistance R
()

Core cross-sectional area Ac (cm2)
Core window area WA (cm2)
Mean length per turn MLT (cm)


noted:
Magnetics
Design and Wire resistivity
(-cm)
Physical
Construction
Inductors Design
Transformer Design
Inductance L (H)
Winding resistance R
()

Core window area WA (cm2)
Mean length per turn MLT (cm)

Transformer Design and Physical
Construction
Magnetics
Design and
Physical
Construction Inclusion of core loss
Inductors Design
Transformer Design
Selection of operating flux 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.

Construction
Magnetics
Design and
Physical
Inductors Design
Transformer Design
windings.

Construction
Magnetics
Design and
Physical
Inductors Design
Transformer Design
windings.

Construction
Magnetics
Design and
Physical
Inductors Design
Transformer Design
windings.

Construction
Magnetics
Design and
Physical
Inductors Design
Transformer Design
windings.

Construction
Magnetics
Design and
Physical The core loss is given as:
Construction
Inductors Design
Transformer Design
Pfe = Kfe (∆B)β Ac ℓm
Typical values for β 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

Construction
Magnetics
Design and
Construction
Inductors Design
Transformer Design


Construction
Magnetics
Design and
Construction
Inductors Design
Transformer Design


Construction
Magnetics
Design and
Construction
Inductors Design
Transformer Design


Construction
Magnetics
Design and
Construction
Inductors Design
Transformer Design


Transformer Design:Flux Density
λ
Flux density B(t) is related to the

v1(t) applied winding voltage according
area λ1
Magnetics
Design and
to Faraday’s Law.
Physical
Construction Denote the volt-seconds applied
Inductors Design
Transformer Design
t1 t2 t to the primary winding during the
positive portion of v1 (t) as λ1 :
Z t
2
λ1 = v1 (t)dt
t1
To attain a given flux density,
the primary turns should be This causes the flux to change
λ
chosen according to from its negative peak to its
∆ positive peak.
λ1
n1 = From Faraday’s law, the peak
2∆BA c
value of the ac component of flux
density is
λ1
∆B =
2n1 Ac
λ

area λ1
Magnetics
Design and
to Faraday’s Law.
Physical
Inductors Design
Transformer Design
Z t
2
λ1 = v1 (t)dt
t1
λ
∆ positive peak.
λ1
2∆BA c
density is
λ1
∆B =
2n1 Ac
λ

area λ1
Magnetics
Design and
to Faraday’s Law.
Physical
Inductors Design
Transformer Design
Z t
2
λ1 = v1 (t)dt
t1
λ
∆ positive peak.
λ1
2∆BA c
density is
λ1
∆B =
2n1 Ac
λ

area λ1
Magnetics
Design and
to Faraday’s Law.
Physical
Inductors Design
Transformer Design
Z t
2
λ1 = v1 (t)dt
t1
λ
∆ positive peak.
λ1
2∆BA c
density is
λ1
∆B =
2n1 Ac
Transformer Design: Copper Losses
Allocate window area between windings in optimum

manner, as described in previous section
Magnetics
Design and
Physical
Total copper loss is then equal to
Construction
Inductors Design ρ(MLT)n 21 I 2tot
Transformer Design Pcu =
WAK u Σ
Where ρ
ρ
I tot = Σ
k nj
n1 I j
Σ
ρλ j=1
∆
Eliminate n1 , using result of previous slide:
ρ λ 21 I 2tot (MLT ) 2
ρλ Pcu = 1
∆ 4K u W A A 2c ∆B
is
Note that copperloss decreases rapidly as ∆B
increased.

Magnetics
Design and
Physical
Construction
WAK u Σ
Where ρ
ρ
I tot = Σ
k nj
n1 I j
Σ
ρλ j=1
∆
ρλ Pcu = 1
∆ 4K u W A A 2c ∆B
is
increased.

Magnetics
Design and
Physical
Construction
WAK u Σ
Where ρ
ρ
I tot = Σ
k nj
n1 I j
Σ
ρλ j=1
∆
ρλ Pcu = 1
∆ 4K u W A A 2c ∆B
is
increased.

Magnetics
Design and
Physical
Construction
WAK u Σ
Where ρ
ρ
I tot = Σ
k nj
n1 I j
Σ
ρλ j=1
∆
ρλ Pcu = 1
∆ 4K u W A A 2c ∆B
is
increased.

Magnetics
Design and
Physical
Construction
WAK u Σ
Where ρ
ρ
I tot = Σ
k nj
n1 I j
Σ
ρλ j=1
∆
ρλ Pcu = 1
∆ 4K u W A A 2c ∆B
is
increased.
Transformer Design:Total Power Loss
Magnetics
Design and There is a value of ∆B that
Physical

Construction
Power
minimizes the total power loss
Inductors Design
loss
Transformer Design Total power loss is given by:
Co
Ptot
fe
sP
ppe
los
Ptot = Pcu + Pfe
r
los
re
Co
s P cu
Where magnetic losses are

β
Optimum ∆B ∆B
Copper losses are:

Magnetics
Design and There is a value of ∆B that
Physical

Construction
Power
minimizes the total power loss
Inductors Design
loss
Transformer Design Total power loss is given by:
Co
Ptot
fe
sP
ppe
los
Ptot = Pcu + Pfe
r
los
re
Co
s P cu

β
Optimum ∆B ∆B
Copper losses are:

Magnetics
Design and
There is a value of ∆B that
Physical
Construction

minimizes the total power

loss
Inductors Design
Power
Transformer Design
loss Total power loss is given by:
Co
Ptot
fe
ss P
ppe
Ptot = Pcu + Pfe

o
r
re l
los
Co
s P cu

β
P fe = K fe(∆B) β A c l m
Optimum ∆B ∆B
Copper losses are:
ρλ
∆ ∆

Magnetics
There is a value of ∆B that
Design and
Physical
minimizes the total power

loss
Construction

Inductors Design Power Total power loss is given by:
Transformer Design loss
Ptot = Pcu + Pfe

Co
Ptot
fe
sP
ppe
los
r lo
re
ss P c
Co

u
P fe = K feβ(∆B) β A c l m
β ∆
Optimum ∆B ∆B Copper losses are:
ρλ
ρ λ 21 I 2tot (MLT ) 1 2∆
Pcu =
∆ 4K u W A A 2c ∆B

Transformer Design: ∆ Optimization
Magnetics
Given that
Design and
Physical
Construction Ptot = Pcu + Pfe
Inductors Design
Transformer Design
How do we find ∆B that minimizes the total power loss

Ptot ?
Then, at the ∆B that minimizes Ptot , we can write
Note: optimum does not necessarily occur where

Pfe = Pcu .
Rather, it occurs where

Magnetics
Given that
Design and
Physical
Construction Ptot = Pcu + Pfe
Inductors Design
Transformer Design

Ptot ?

Pfe = Pcu .

Given that
Magnetics
Design and
Physical Ptot = Pcu + Pfe
Construction
Inductors Design
Transformer Design
Ptot ?

dPtot dP fe dPcu
= + =0
d(∆B) d(∆B) d(∆B)
Pfe = Pcu .
∆ ∆

Given that
Magnetics
Design and
Physical Ptot = Pcu + Pfe
Construction
Inductors Design
Transformer Design
Ptot ?

dPtot dP fe dPcu
= + =0
d(∆B) d(∆B) d(∆B)
Pfe = Pcu .
∆ ∆

Given that
Magnetics
Design and
Physical
Ptot = Pcu + Pfe
Construction
Inductors Design
Transformer Design How do we find ∆B that minimizes the total power loss
Ptot ?

dPtot dPfe dPcu
= + =0
d(∆B) d(∆B) d(∆B)
∆ ∆ ∆
Pfe = Pcu .
∆ dP fe ∆ dPcu
=–
d(∆B) d(∆B)

Transformer Design: Core and Copper Loss
Derivatives
Magnetics
Design and
Physical For the core loss we have ∆ β ρλ
Construction
Inductors Design
β
P fe = K fe(∆B) A c l m ρλ
Transformer Design
dP fe β–1
= βK fe (∆B) Aclm ρλ
d(∆B) β
β ∆ ∆ ρλ
∆
For the copper loss we have ∆
∆ ∆
Now, substitute into ∆ ∆
β
ρλ
∆ β
ρλ β
∆
β

Derivatives
For the core loss we have ∆ β ρλ

Magnetics
P fe = K fe(∆B) A c l m β ρλ
Design and
Physical
Construction
dP fe β–1
Inductors Design
Transformer Design = βK fe (∆B) Aclm ρλ
d(∆B) β
β ∆ ∆ ρλ
∆
For the copper loss we have ∆
∆ β ρ λ 21 I 2tot (MLT ) 1 2
Pcu =
4K u W A A 2c ∆B∆ ∆
∆ ∆
β ∆ β
dPcu ρλ 21 I 2tot (MLT)
∆ =–2 ρλ (∆B) – 3 β
d(∆B) ∆ 4K u W A A 2c β
ρλ β
∆
Now, substitute into β

∆ ∆
β
EE410 Dept. ρλ
∆ of Electrical Engineering - 18 - T. Marisa | tmarisa@uz.ac.zw
Derivatives
For the core loss we have ∆ β ρλ
P fe = K fe(∆B) A c l m β ρλ
Magnetics
Design and
Physical
Construction dP fe β–1
= βK fe (∆B) Aclm ρλ
Inductors Design
d(∆B) β
Transformer Design
β ∆ ∆ ρλ
∆
For the copper
β loss we have
∆
∆ ρλ
∆ β ρ λ 21 I 2tot (MLT ) 1 2
Pcu =
4K u W A A 2c ∆B∆ ∆
∆ ∆
β ∆ β
β ∆ β cu
dP ρλ 21 I 2tot (MLT) – ρλ
3 β
∆ =–2 2 (∆B)
∆ d(∆B) ρλ
∆ 4K u ∆ W A A c β
ρλ β
∆
Now, substitute into β

∆ ∆
dP fe dPcu
=–
β
d(∆B) d(∆B)
ρλ
∆
EE410 Dept. of Electrical Engineering β - 18 - T. Marisa | tmarisa@uz.ac.zw
Transformer Design: ρλ
∆ β Core and Copper Loss
Derivatives
β
β ∆ ρλ
∆
Magnetics
∆
Design and
Physical
Construction
∆B for a∆given core and

Inductors Design
Transformer Design The we solve for the optimum ∆
application which is
1
β+2
ρλ 21 I 2tot (MLT ) 1
∆B =
2K u W A A 3c l m βK fe

Transformer Design: Minimum Total Loss
Derivatives
Magnetics
Design and
Physical
Substitute optimum ∆B into expressions for Pcu and
Construction
Inductors Design
Pfe .
Transformer Design
The total loss is:
We can rearrange as follows:
Left side: terms depend on core geometry.

Right side: terms depend on specifications of the
application

Derivatives

Magnetics
Design and Pfe .
Physical
Construction
The total loss is:
Inductors Design

Transformer Design
β
β 2
β+2
2
β+2
ρλ 21 I 2tot (MLT ) β –
β+2 β β+2
Ptot = A c l m K fe +
4K u W A A 2c 2 2

β
β β β
β β
β β β β ρλ
β β β
application

Derivatives
Pfe .
Magnetics
Design and
Physical
The total loss is:

Construction
Inductors Design ββ
ββ 2
Transformer Design
2 2 β β+ 2
2 ρλ
ρλ1 I tot (MLT ) ββ – β β+ 2 β β β+ 2
Ptot = A c l m K fe β β+ 2 + β
4K u W A A 2c 2 2

ββ + 2
– β
β – 1)/β
β ββ β β
WA Ac
2(β
ββ –β
β+2 ββ
2
ββ + 2 ρλ 2/β
ρλ 21 I 2tot K fe
β + =
(MLT )l m2/β 2 2 β β + 2β/β
4K u Ptot

application
Derivatives
Pfe .
Magnetics
Design and
Physical
The total loss is:

Construction
ββ 2
Transformer Design
2 2 β β+ 2
2 ρλ
4K u W A A 2c 2 2

ββ + 2
– β
β – 1)/β
β ββ β β
WA Ac
2(β
ββ –β
β+2 ββ
2
ββ + 2 ρλ 2/β
ρλ 21 I 2tot K fe
β + =
(MLT )l m2/β 2 2 β β + 2β/β
4K u Ptot

application
Derivatives
Pfe .
Magnetics
Design and
Physical
The total loss is:

Construction
ββ 2
Transformer Design
2 2 β β+ 2
2 ρλ
4K u W A A 2c 2 2

ββ + 2
– β
β – 1)/β
β ββ β β
WA Ac
2(β
ββ –β
β+2 ββ
2
ββ + 2 ρλ 2/β
ρλ 21 I 2tot K fe
β + =
(MLT )l m2/β 2 2 β β + 2β/β
4K u Ptot

application
Transformer Design: Core Geometrical
Constant Kgfe
Magnetics
Design and
We define :
Physical β+2
–
Construction β β
2(β – 1)/β – 2
Inductors Design WA Ac β β+2 β β+2
Transformer Design K gfe = +
(MLT)l m2/β 2 2
Design procedure: select a core that satisfies:

β
ρλ
≥
Kgfe is similar to the βKg geometrical
β constant used for
the inductor:
• Kg is used when Bmax is specified.
• Kgfe is used when ∆B is to be chosen to minimize total
loss.


Constant Kgfe
We define :
Magnetics β+2
– β
Design and β β
2(β – 1)/β – 2 β
Physical WA Ac β β +β 2 β β β+2
Construction K gfe = + β β β β
Inductors Design
(MLT)l m2/β 2 β 2
Transformer Design

β
ρλ ρλ 21 I 2tot K fe
2/β
≥
β ≥
K gfe β
β + 2 /β
4K u Ptot
Kgfe is similar to the Kg geometrical constant used for

the inductor:
• Kgfe is used when
∆B is to be chosen to minimize total

loss.

Constant Kgfe
We define :
Magnetics β+2
– β
Design and β β
2(β – 1)/β – 2 β
Inductors Design
(MLT)l m2/β 2 β 2
Transformer Design

β
2/β
≥
β ≥
K gfe β
β + 2 /β
4K u Ptot

the inductor:

loss.

Constant Kgfe
We define :
Magnetics β+2
– β
Design and β β
2(β – 1)/β – 2 β
Inductors Design
(MLT)l m2/β 2 β 2
Transformer Design

β
2/β
≥
β ≥
K gfe β
β + 2 /β
4K u Ptot

the inductor:

loss.

Constant Kgfe
We define :
Magnetics β+2
– β
Design and β β
2(β – 1)/β – 2 β
Inductors Design
(MLT)l m2/β 2 β 2
Transformer Design

β
2/β
≥
β ≥
K gfe β
β + 2 /β
4K u Ptot

the inductor:

loss.


noted:
Magnetics
Design and
Physical Wire effective resistivity (-cm)
Construction
Inductors Design Total rms winding current, ref to pri Itot (A)
Transformer Design
Desired turns ratios n2/n1, n3/n1, etc.
Applied pri volt-sec 1 (V-sec)
Allowed total power dissipation Ptot (W)
Core loss exponent
Core loss coefficient Kfe (W/cm3T)


Other core dimensions are expressed in cm:

Magnetics Core window area WA (cm2)
Design and
Physical Mean length per turn MLT (cm)
Construction
Inductors Design
Magnetic path length le (cm)
Transformer Design
Wire areas Aw1, … (cm2)
Peak ac flux density B (T)
Just like with inductors, the use of centimeters rather

than meters requires that appropriate factors be added
to the design equations.


Other core dimensions are expressed in cm:

Magnetics Core window area WA (cm2)
Design and
Physical Mean length per turn MLT (cm)
Construction
Inductors Design
Magnetic path length le (cm)
Transformer Design
Wire areas Aw1, … (cm2)
Peak ac flux density B (T)
Just like with inductors, the use of centimeters rather

than meters requires that appropriate factors be added
to the design equations.

Design of Winding Geometry to Minimize
Proximity Loss
Interleaving windings can significantly reduce the
Magnetics proximity loss when the winding currents are in phase,
Design and
Physical such as in the transformers of buck- derived converters
Construction
Inductors Design
or other converters
Transformer Design
In some converters (such as flyback converters) the
winding currents are out of phase. Interleaving then
does little to reduce the peak MMF and proximity loss.
For sinusoidal winding currents, there is an optimal
conductor thickness near ϕ = 1 that minimizes copper
loss.
Minimize the number of layers. Use a core geometry
that maximizes the width lw of windings.
Minimize the amount of copper in vicinity of high MMF
portions of the windings
Proximity Loss
Design and
Construction
Inductors Design
or other converters
Transformer Design
loss.
Proximity Loss
Design and
Construction
Inductors Design
or other converters
Transformer Design
loss.
Proximity Loss
Design and
Construction
Inductors Design
or other converters
Transformer Design
loss.
Proximity Loss
Design and
Construction
Inductors Design
or other converters
Transformer Design
loss.
Winding Wire Selection: Minimize Proximity
Loss
Magnetics
Design and
Physical Litz wire is a type of cable used in electronics to carry
Construction
Inductors Design
alternating current.
Transformer Design
The wire is designed to reduce the skin effect and
proximity effect losses in conductors used at
frequencies up to about 1 MHz.
A way to increase conductor area while maintaining low
proximity losses.
Many strands of small-gauge wire are bundled together
and are externally connected in parallel.

Loss
Use of Litz wire

Magnetics
Design and Strands are twisted, or transposed, so that each strand
Physical
Construction passes equally through each position on inside and
Inductors Design
Transformer Design outside of bundle.
This prevents circulation of currents between strands.
Strand diameter should be sufficiently smaller than skin
depth
The Litz wire bundle itself is composed of multiple
layers
• Advantage: when properly sized, can significantly
reduce proximity loss.
• Disadvantage: increased cost and decreased amount
of copper within core window.

Loss
Use of Litz wire

Magnetics
Physical
Inductors Design
depth
layers

Loss
Use of Litz wire

Magnetics
Physical
Inductors Design
depth
layers

Loss
Use of Litz wire

Magnetics
Physical
Inductors Design
depth
layers

Loss
Use of Litz wire

Magnetics
Physical
Inductors Design
depth
layers

Loss
Use of Litz wire

Magnetics
Physical
Inductors Design
depth
layers

Loss
Magnetics
Design and
Physical
Construction
Inductors Design
Transformer Design

Loss
Magnetics
Design and
Physical
Construction
Inductors Design
Transformer Design

Magnetics
Design and
Physical
Construction
Inductors Design
End of lecture.
Transformer Design
Questions ?

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Power Electronics

Dr. T. Marisa <tmarisa@uz.ac.zw>

Department of Electrical Engineering

1 Magnetics Design and Physical Construction

EE410 Dept. of Electrical Engineering -2- T. Marisa | tmarisa@uz.ac.zw

1 Magnetics Design and Physical Construction

EE410 Dept. of Electrical Engineering -3- T. Marisa | tmarisa@uz.ac.zw

EE410 Dept. of Electrical Engineering -4- T. Marisa | tmarisa@uz.ac.zw

EE410 Dept. of Electrical Engineering -4- T. Marisa | tmarisa@uz.ac.zw

EE410 Dept. of Electrical Engineering -4- T. Marisa | tmarisa@uz.ac.zw

EE410 Dept. of Electrical Engineering -4- T. Marisa | tmarisa@uz.ac.zw

have space constraints.

Figure: Cross-sections of typical planar and deep-diffused diode

EE410 Dept. of Electrical Engineering -5- T. Marisa | tmarisa@uz.ac.zw

have space constraints.

Figure: Cross-sections of typical planar and deep-diffused diode

EE410 Dept. of Electrical Engineering -5- T. Marisa | tmarisa@uz.ac.zw

have space constraints.

Figure: Cross-sections of typical planar and deep-diffused diode

EE410 Dept. of Electrical Engineering -5- T. Marisa | tmarisa@uz.ac.zw

Our design constraints are:

EE410 Dept. of Electrical Engineering -8- T. Marisa | tmarisa@uz.ac.zw

Our design constraints are:

EE410 Dept. of Electrical Engineering -8- T. Marisa | tmarisa@uz.ac.zw

Our design constraints are:

EE410 Dept. of Electrical Engineering -8- T. Marisa | tmarisa@uz.ac.zw

Our design constraints are:

EE410 Dept. of Electrical Engineering -8- T. Marisa | tmarisa@uz.ac.zw

Our design constraints are:

EE410 Dept. of Electrical Engineering -8- T. Marisa | tmarisa@uz.ac.zw

Elimination of n, ℓg , and AW leads to

EE410 Dept. of Electrical Engineering -9- T. Marisa | tmarisa@uz.ac.zw

Elimination of n, ℓg , and AW leads to

EE410 Dept. of Electrical Engineering -9- T. Marisa | tmarisa@uz.ac.zw

Elimination of n, ℓg , and AW leads to

EE410 Dept. of Electrical Engineering -9- T. Marisa | tmarisa@uz.ac.zw

Elimination of n, ℓg , and AW leads to

EE410 Dept. of Electrical Engineering -9- T. Marisa | tmarisa@uz.ac.zw

Elimination of n, ℓg , and AW leads to

EE410 Dept. of Electrical Engineering -9- T. Marisa | tmarisa@uz.ac.zw

The following quantities are specified, using the units

The core dimensions are expressed in cm:

The use of centimeters rather than meters requires that

EE410 Dept. of Electrical Engineering - 11 - T. Marisa | tmarisa@uz.ac.zw

The following quantities are specified, using the units

The core dimensions are expressed in cm:

EE410 Dept. of Electrical Engineering - 11 - T. Marisa | tmarisa@uz.ac.zw

The following quantities are specified, using the units

The core dimensions are expressed in cm:

EE410 Dept. of Electrical Engineering - 11 - T. Marisa | tmarisa@uz.ac.zw

EE410 Dept. of Electrical Engineering - 12 - T. Marisa | tmarisa@uz.ac.zw

EE410 Dept. of Electrical Engineering - 12 - T. Marisa | tmarisa@uz.ac.zw

EE410 Dept. of Electrical Engineering - 12 - T. Marisa | tmarisa@uz.ac.zw

EE410 Dept. of Electrical Engineering - 12 - T. Marisa | tmarisa@uz.ac.zw

EE410 Dept. of Electrical Engineering - 12 - T. Marisa | tmarisa@uz.ac.zw

Typical values for β for ferrite materials: 2.6 or 2.7

EE410 Dept. of Electrical Engineering - 13 - T. Marisa | tmarisa@uz.ac.zw

Typical values for β for ferrite materials: 2.6 or 2.7

EE410 Dept. of Electrical Engineering - 13 - T. Marisa | tmarisa@uz.ac.zw

Typical values for β for ferrite materials: 2.6 or 2.7

EE410 Dept. of Electrical Engineering - 13 - T. Marisa | tmarisa@uz.ac.zw

Typical values for β for ferrite materials: 2.6 or 2.7