Experimental Comparison of Mega Flux and JNEX

Inductors in High Power dc-dc Converter of Hybrid

Electric Vehicles
Bong-Gi You, Byoung-Kuk Lee Sang-Won Lee, Gwang-Bo Choi Dong-Wook Yoo
Energy Mechatronics Laboratory R&D Center Renewable Energy Research Group
Sungkyunkwan Univ. Changsung Corporation KERI
Suwon, Korea Incheon, Korea Changwon, Korea
bongary@skku.edu; swlee@changsung.com; dwyoo@keri.re.kr
bkleeskku@skku.edu gbchoi@changsung.com

Abstract-In this paper, the characteristics of Mega-Flux® and
JNEX® cores are compared to the inductor of buck-boost
converter for Hybrid Electric Vehicles (HEVs). The core losses
were measured at various flux densities at 15kHz and the
magnetic simulations of Mega-Flux® core were fulfilled. Magnetic
simulations were tried in terms of magnetic flux saturation level,
AC copper loss due to flux leakage and temperature rise at the
condition of the water coolant of 50 degrees Celsius. Similar
operating tests with HEVs dc-dc converter were fulfilled with
established 40kWatt dc-dc converter system. Under the
specifications of boost converter for 40kW, the power inductors
were designed with Mega-Flux® core, JNEX® core and the
experimental results were provided with the respect of dc bias
characteristics, temperature rise and acoustic noise of the
inductor.
Electro-Magnetic-Interference (EMI) and induction heating
from the astray flux [1]. FINEMET® nano-crystalline from
Hitachi and ferrite cores also have the same behavior at the
point of discrete air gaps. However, Mega Flux® from CSC,
distributed air gap powder cores whose composition is Fe-
6.5%Si, have the similar magnetic behaviors as JNEX® cores
while minimizing astray flux [2].
In 2009, the 3rd generation of THS II has adopted High
Density Magnetic Composite (HDMC) cores for their
inductor, which are molded out of iron particles and
surrounded by an insulating layer. HDMC are powder cores
similar with Mega Flux® cores, so mass production processes
are simpler than that of conventional electrical steel sheets [3].

Keywords- HEVs; EV; Boost Inductor; High power dc dc

converter; Low core loss; Thermal stability
I. INTRODUCTION
The global warming has close relationship with CO2
emission and energy consumption. Especially, vehicle’s high
fuel efficiency can dramatically reduce CO2 emission by way
of Zero Emission Vehicles (ZEVs) and Hybrid Electric
Vehicles (HEVs). The appearance of HEVs can be a
temporary alternative for eco-friendly vehicles from the
exquisite combination of Internal Combustion (IC) engines
and electric motors.
In general, HEVs need the AC motor driving power system Fig. 1. Manufacturing Process of HDMC core [3]
such as the high voltage battery packs, the bi-directional boost
Table I shows the comparison of the various core materials,
type dc-dc converter, the 3-phase inverter and AC motor etc.,
and provides an explanation for why JNEX® and Mega Flux®
for the essential mission of enhancing gas mileage. The
cores are chosen in the present paper [4].
additional dc-dc boost converter between the battery and the
TABLE I
three phase inverter has been applied in the present models of Characteristic Comparison of Cores for HEVs
the Toyota Hybrid System II (THS-II) in HEVs to obtain the
higher stabilized DC voltage and the higher efficiency motor JNEX® FINEMET® Ferrite Mega-Flux®
drive. Typically, in 2003 version of THS-II, JFE’s JNEX® Bsat ◎ ○ × ◎
cores were used as the core material of Inductor of buck-boost Thermal Stability ◎ ○ △ ◎
converter. JNEX® cores are the non-oriented magnetic steel EMI × × × ○
sheets manufactured by Chemical Vapor Deposition (CVD)
Size ◎ ○ × ○
Acoustic Noise ○ △ △ ◎
method to increase Si content by 6.5%. Unfortunately, JNEX® Core Loss ○ ◎ ◎ ○
cores need discrete air gaps to prevent flux saturation of power Note : ◎ – Best, ○ – Better, △ – Good, ×– Bad.
inductor due to its high permeability, which can make radiated

978-1-61284-247-9/11/$26.00 ©2011 IEEE

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 In this paper, as the potential candidates for the inductor of
boost converter for HEVs, the characteristics of Mega Flux®
core, JNEX® cores are compared in detail. The core losses are
measured at various flux densities at 15kHz and the magnetic
simulations of Mega-Flux® core were fulfilled. Under the
specifications of boost converter for 40kW, the power
inductors were designed with Mega Flux® cores, JNEX® cores
and the experimental results were provided with respect to dc
bias characteristics, temperature rise property and acoustic
noise.
II. CORE MATERIALS
A. The roles of air gaps in power inductor
The main roles of power inductor are to store energy during
one portion of each switching period and return this energy to
the circuit during another portion of the period as a electric
field which is made from flux swing. Inductance of an cored
inductor is not a constant at a given biased current. As it were,
the effective permeability, slope of B-H curve, is dominant
factor of inductance and this permeability can be expressed as
a function of magnetizing force and initial permeability (1).
L = f (ueff , N , Ac , l ) , u eff = f (u i , H , Bsat )
Following equations will show that the relationship of air
gap effect vs. magnetizing force.
ni = Φ ( Rc + Rg ) (2)
Φ sat = Bsat ⋅ Ac (3)
Bsat Ac
isat = ( Rc + Rg ) (4)
n diffusion, silicon contents can be increased from 3% by 6.5%.
There are two methods to insert air gaps in cores. One is to
insert a bulk air gap by cutting the path of magnetic flux
(Ferrite, JNEX® core, FINEMET®, Amorphous strip, electrical
steel sheet cores), and the other is to make distributed air gaps
by insulation of metal alloy powders (Mega Flux®, MPP,
Sendust, HF, Iron). Bulk air gap cores have “B: sharp
saturation” characteristics, whose permeability rolls off
abruptly at the point of saturation level. On the other hand,
distributed air gap cores have “A: soft saturation”
characteristics, which exhibits a gradual reduction of
incremental permeability until finally the core is completely
saturated (Fig. 2) [4].
Fig. 2. DC Bias Characteristics
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B. Core losses in power inductor
The total core losses of various cores consist of the
hysteresis losses, eddy current losses and residual losses.
(5)
P( B, f ) = Ph (a ⋅ Bmax ⋅ f ) + Pr (c ⋅ f ) + Pe (e ⋅ f 2 )
Where, Ph : hysteresis loss, Pr : residual loss, Pe : eddy current loss
The higher resistivity of the core materials makes the lower
the eddy current losses. The dominant losses in metal alloyed
strip and powdered cores are eddy current losses for their low
resistivity of core material. The core losses of metal alloyed
cores hardly change with various temperatures. When it comes
to ferrite, eddy current losses are dramatically low for their
high resistivity. But the core loss of ferrite sensitively changes
according to the temperature. The core losses can be expressed
as the function of flux swing and frequency by using a power
law equation [5], [6]
P v ( t ) = a ⋅ f b ⋅ B peak
c
(6)
Where Bpeak is the peak flux amplitude (1/2 ΔB = Bpeak),
Pv (t ) is the average core loss per unit volume, and f is the
switching frequency. When it comes to Mega Flux core, (6)
equation can be expressed as P(mW / cc) = 1.83⋅ f 1.48 ⋅ Bpeak
2.13
(1) C. Electrical Steel Sheet Cores
With all their excellent performance in terms of near zero
magneto-striction coefficient, high resistivity and high thermal
stability Fe-6.5%Si sheet cores had not been available due to
their brittle mechanical properties. Before appearance of the
super cores, the only commercialized Silicon-Steel cores were
Fe-3%Si sheet cores. The super cores from JFE are made by
Chemical Vaporized Deposition (CVD) process. By thermal
JNEX® is a non-oriented electrical steel core with a 6.5% Si
and magneto-striction is virtually zero. Fig. 3 shows JNEX®
cores have lower noise than 3%Si sheet core with near zero
magneto-striction. JNEX® cores had been used as the core
materials of buck-boost inductor in Prius II(2003). JNHF®
cores are a gradient-type Si steel sheet where the Si content is
6.5% only at the sheet surface and is decreased in the sheet
thickness direction. This gradient Si% structure leads lower
core losses than JNEX® in the high frequency above 10kHz
[7].
Fig. 3. Noise comparison vs Si% in steel sheet core [7]
 D. Powder Cores Mega Flux® cores are made from 93.5% iron and 6.5%
Distributed air gap structure gives many invisible silicon alloyed powder. The moree effective permeability of
advantages such as minimized fringing fluxx, soft saturation, Mega Flux® survives at extremely y high biased current level.
low acoustic noise level and low core llosses. But low The high manufacturing pressure of 20Ton/cm2 has limited
permeability needs more winding turns thhan bulky cores, the usage of metal alloy powder co ores in large current SMPS
which is caused from too many distributed air gap for low core applications. But any large currrent and high frequency
losses. Table II show various powdered corees such as MPP, applications can be designed by staacking the powdered Mega
High Flux, Sendust, Mega Flux® and Iron C Core. MPP cores Flux® block cores. Figure 4 shows thet relationship of magnetic
are Moly-Permalloy Powdered, a low-loss alteernative to ferrite properties with Si contents in Fee-Si alloy. These excellent
cores, typically consisting of 78% nickel, 188% iron and 4% properties of Mega Flux® are attributed to near-zero magneto-
molybdenum alloy powder. MPP cores exhibit highly striction, anisotropy(K1), higher ressistivity of Fe-6.5%Si alloy
approved stability in temperature, inductancee under high DC as show in Fig. 4 [8]. Mega Flu ux® cores pressed with no
biased condition. High-Flux cores are made from 50% nickel organic binder have significantly lower
l core loss than super
and 50% iron alloy powder. The 1.5 Tesla saaturation level of cores at high frequency such as over 10kHz, showing no
High Flux cores bring higher energy storagge capability and thermal aging effects. Table III sh hows the detailed magnetic
more effective permeability than MPP and Seendust. Excellent properties of JNEX® and Mega Flux x® Cores.
DC bias characteristics and relatively low ccore losses offer TABLE IIII
high power density. Sendust is a magnetic m metal powder that Comparison of JNEX and Mega
M Flux Core [9]
was invented at Tohoku Imperial University iin Sendai, Japan, Magnetic Material Siliccon Steel Powder Core
about 1936 as an alternative to permallloy in inductor Manufacturer JFE Chang Sung Cop.
applications for SMPS. Composition of Senndust is typically Material 10JNEX900 Mega Flux
Composition 6.5
5% Fe-Si Fe-Si
85% iron, 9% silicon and 6% aluminum. Duue to its chemical
Bsat (T) 1.80 1.6
composition and crystallographic structure Sendust exhibits Rel. Permeability
near zero magneto-striction and zero m magnetocrystalline 900 26-90
(100 ºC @20kHz)
anisotropy constant K1. Near zero magnneto-striction of Curie temp. (ºC) 700 725
Sendust enables to prevent audible noise in indductors. Cont. operating temperature (ºC) 150* 200
Thermal cond. (W m-1 K-1) 18.6**
1 11.4***
TABLE II Specific Heat Capacity [J/(K kg)] 536 130
Core Materials comparison
Density [g/cm3] 7.49 7.0
Class Material μi
B
max
Curie *λ
-6 Fre. Manufacturer
Resistivity [Ω m] 82 × 10-6
0.8 5 × 106
(℃) (10 )
[T] Micro powder
Lamination Thickness [mm] 0.1-0.2
0
MPP 0.7 450 0 2MHz (50μm)
(Ni-Fe-Mo alloy)
Core Fill Factor 0.9 1
High-Flux 1.5 500 0 1MHz
Changsung
(Ni-Fe alloy) Magneto-striction [ppm] 0.1 0.03
14~550 Magnetics
Powder Sendust 1.0 500 0 10MHz Core Loss @0.1T, 20kHz
Arnold 180 124
Core (Fe-Si-Al alloy)
[kW/m3]
Mega-Flux 1.6 725 0.1 10MHz
(Fe-Si alloy) * limited by the lamination epoxy, ** along laminations,
l ***isotropic
Iron powder (Fe) 10~75 2.0 770 10kHz Micrometals
Carbonyl Iron 35~50 2.0 770 10MHz
III. SIMUATION AND ANALY
YSIS OF POWER INDUCTOR
METGLAS 2605SC 3,000 1.5 370 27.0 250kHz Hitachi
METGLAS 2714A 100,000 0.5 205 250kHz
A. Inductor losses
Sheet Fe-3%Si (unoriented) 400 1.8 740 7.8 1kHz Magnetic simulations were carriied out as the proposed at
Core Postech
Fe-3%Si (oriented) 1,500 1.8 740 -0.8 1kHz
condition of 70A rated current with
h the ripple current of 40A.
JNEX(Fe-6.5%Si)
JNHF(Fe-6.5%Si)
400 1.6 725 0.1 1MHz JFE Core losses, DC copper loss and other
o astray losses such as
AC copper losses were simulated d. Boundary conditions for
* Magneto-striction coefficient
simulation are as follows;

z Boost converter : Vin = 20 00V, Vout = 400V

z Inductor current : Irms = 70
0A, Iripple = 40A
z Switching frequency = 15 5kHz
z Room temperature = 100℃
z Cooling method = Water cooling (50℃, 8LPM)
z

Fig. 5 shows the simulation result of magnetic flux

distribution at the current of 100A.
Fig. 4. Magnetic properties of Fe-Si alloyy [8]

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 TABLE IVV
Calculation of Mega Flux
x Inductor Loss
L (µH) 176.4
Δi (A) 40
N·Ac 377.3
1/2·ΔB (G) 935
Core Loss (mW/cc) 157
Core Loss (W) 17.9
RMS Current (A) 70
Copper Resistance (mΩ) 13.8
DC Copper Loss (W) 71.8
AC Copper Loss (W)* 36.2
Total Loss (W) 125.9
* Obtained by using Finite Elem
ment Method (FEM)
Fig. 5. Simulation of magnetic flux distribbution
B. Temperaturre rising
Fig. 6 shows astray AC copper loss distribuutions and the AC Fig. 8 shows the simulation resullt of temperature rise at the
copper losses of 36.2Watt were obtained by using the Finite above boundary condition. The botttom is cooled with 8 litter
Element Method (FEM). per minute (LPM). Temperature satturation was also simulated
by using the FEM. The temperaturre of Mega Flux® core was
84 degrees Celsius and the peak po oint was 94 degrees Celsius
between the two coils. To predict th
he temperature distributions
of Inductor, 4 points were chosen.

Fig.6. Simulation of AC copper losss

ΔB was used to determine the flux swinng of fabricated

Fig. 8. Simulation result of tem
mperature saturation.
Mega flux® cores
Inductor. Fig. 7 is the experimental result of M
losses at fixed 15kHz frequency with varyinng magnetic flux
swing. By using the value of 1/2•ΔB at the Taable IV and Fig. 7 IV. EXPERIMENT
TAL RESULTS
the core losses could be calculated. Table IIV describes the A. Magnetic parametters of inductor
total Inductor losses from the calculated reesult of the core
Fig. 9 shows the fabrication prrocess of Inductor. Firstly,
losses, DC copper losses and AC copper lossees.
cores were assembled with bobbiin materials and edgewise
coils were wound. After assembling g, the bonding strength was
@15kHz enhanced with curing process at 120 degrees Celsius for
JNEX 2hours. Finally, core and coil were inserted to aluminum case
1000 Mega-Flux
and molding materials were potted, which could help good
thermal transfer to the water cooling bottom. Fig. 10 is the
100
picture of the 40kW Inductor fabriccated from Mega flux® and
Core Loss [w/kg]

JNEX® cores. The weight and diimensional parameters are

10
shown in Table V.

0.1

100 1k 10k
FluX Density [Gauss]

Fig. 7. Core losses vs. the flux density at 115kHz

Fig. 9. Fabrication proceess of inductor

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 profiles are for 1minute at 12 20Ampere, 23minutes at
80Ampere, 36minutes at 40Amperre. The Fig. 14 shows the
loading profiles are grouped as 3 parts by using the EPA’s
urban dynamometer driving schedu ule (UDDS) only when the
vehicle is moving. Fig. 15 shows the current wave forms of
each 3 parts.
100

90
Durration : 1,369 sec
(a) JNEX® core inductor (b) Mega Fllux® core inductor 80 Disstance : 12km
Fig. 10. Prototype of power inductor for 36kW booost converter Aveerage speed : 31.5km/h

Vehicle speed (km/hour)

70

60
TABLE V 50
Detail Parameters of Power Inductorss
40
JNEX® Mega Flux® 30
core core 20
Sectional Area(cm2) 3.94 5.25 10
Path Length(cm) 22.9 25.9 0
Core Volume(cc) 90 126.2 0 200 400 600 800 1000 1200 1400
Test time((sec)
Core Weight(kg) 0.667 0.866 Fig. 13. EPA urban dynamomeeter driving schedule
Copper Weight(kg) 0.830 0.846
Outer Dimension(cm) 143*110*55 130*116*47
TABLE VI V
Total Weight(kg)* 2.3686 2.18 Approximation of Load
ding Profiles
*
include potting materiall and aluminum case
Speed Time Occupation As off 60 minute Current Power
(km/h) (sec) Rate (%) (min) (A) (kW)
B. Inductor test system 0~2 15 1.72 1.7 1 120 24
3~10 74 8.49
Performance of the Inductor was verifi fied through the 10~20 94 10.78
experiments in this section. The conventionall boost converter 38.9 23 80 16
20~30 145 16.63
was used for experiments as shown in Fig. 111. DC source was 30~40 26 2.98
used as the high voltage battery pack. The test system was 40~ 518 59.40 59.4 36 40 8
Total 872 100 100 60 - -
established as shown in Fig. 12 and the operration parameters
were the same with chapter III. Current
(A)
120

80

40
1min

23min 36
6min

23 24 60 Time
(min)
Fig. 11. Topology of testing system
m
Fig. 14. Loading profiles

(a) 40Amperre

Fig. 12. Prototype of 40kW boost converter ffor HEVs

C. Temperature rise test (b) 80Ampere

wer inductor is the
In Fig. 13 the most severe condition of pow
moment of starting & accelerating after idliing stop. At that
time the current of power inductor will be thhe peak for a few
seconds. Table VI shows the operating paraameters and load (c) 120Ampeere
Fig. 15. Inductor operating current

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 The fabricated Mega-Flux® core, JNEX® core inductors 80

were operated at 100 degree Celsius of ambient temperature to 70

63.9
make similar condition to near combustion engine and cooled 60
by water coolant of 50 degree of Celsius at 8 liter per minute.
50

Noise (dB)
The temperature rise in core, coil and potting materials of
Mega-Flux® core and JNEX® core inductors were measured 40

by infra-red camera and thermal recorder. The saturated 30

temperature distributions were measured using a infra-red 20

camera (Fig. 16, Fig.17). Peak point was about 113 degrees
10
Celsius between the two coils.
0
0 3000 6000 9000 12000 15000 18000
Frequency (Hz)

Fig. 19. FFT analysis of Mega Flux inductor

V. COMPARISONS AND DISCUSSIONS

Fig. 20 shows that DC bias characteristics were almost the

same at the low current range by 200Ampere but Mega-Flux®
core inductor survived the JNEX® core inductor over the
200Ampere range.
Fig. 16. Temperature rise measurement of inductor
using infra red camera (25℃) 200
Mega-Flux
180 JNEX

160
Core
Coil
Inductance(uH)

140

120

100

80

60
50 100 150 200 250 300 350 400
Fig. 17. Temperature rise measurement of inductor Current (A)
using thermal couple wire (100℃) Fig. 20. DC bias characteristics of
Mega-Flux® core and JNEX® core inductors

D. Noise measurement
The acoustic noise was measured and analyzed by FFT at
the anechoic chamber under 30dB back ground noise level.
Inside the anechoic chamber, as shown in Fig. 18, fabricated
inductor was installed with operating boost converter with a
switching frequency of 15kHz. FFT analysis shows the
coincidence with the switching frequency and maximum noisy
frequency in Fig. 19.
Fig. 18. Noise measuring system
The maximum temperature rising point was recorded as Fig.
21 when 40kW dc-dc converter was operated at the loading
profiles (Fig. 14). The temperature rise of Mega-Flux® core
inductor was 99.9 degree of Celsius, while JNEX® core was
131.6 degree of Celsius at the rated current of 80Ampere. The
main reason why Mega-Flux® core inductor recorded the
lower temperature than JNEX® core could be due to thermal
conductivity [9]. JNEX® core have the higher thermal
conductivity than Mega-Flux® core by 7.2 W/m-K. The
lamination direction has a significant impact on the thermal
conductivity and subsequent heating of the inductor core. The
JNEX® core is developed using a stamping process. The
thermal conductivity of the material is 18.6 W/m-K along the
lamination [10] and approximately 1W/m-K against the
lamination. But the Mega-Flux® core is made from metal
alloyed powder compression process [11]. So thermal
conductivity of Mega-Flux® core is isotropic and measured by
11.4W/m-K. The lamination direction is a critical parameter
regarding the inductor mounting as it affects both thermal
conductivity and thermal path length.

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 below the saturation flux level and can predict the temperature
160
rise.
o
155.3 C The core losses are measured at various flux densities at
150
Mega-Flux
15kHz and the magnetic simulations of Mega-Flux® core were
140
131.6 C
o JNEX fulfilled. Under the specifications of boost converter for
130
40kW, the power inductors were designed with Mega-Flux®
Temperature ( C)

120
core, JNEX® core and the experimental results were provided
o

o
115.8 C
110
99.9 C
o
with the respect of dc bias characteristics, temperature rise
100
property and acoustic noise of inductor. DC bias
90
78.4 C
o characteristics were almost the same at the low current range
80
by 200Ampere but Mega-Flux® core inductor survived the
70 o
73 C JNEX® core inductor over the 200Ampere range. The
60 temperature rise of Mega-Flux® core inductor recorded
50
0 10 20 30 40 50 60
30degree of Celsius lower than JNEX® core inductor at the
Time (min) rated current of 80Ampere due to the isotropic thermal
properties of Mega Flux core and higher core losses of JNEX®
core. The acoustic noise level result was almost the same but
Fig. 21. Temperature rise of Mega-Flux® core and JNEX® core inductors structural design will have serious effect.
Acoustic noise was measured operating from 30Ampere to
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core inductor shows the uniform flux density distributions

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