5.

Design of Magnetic Components

5.1 Design of Transformer:
The conversion process in power electronics requires the use of transformers, which have a significant effect upon the overall performance and efficiency of the system. Accordingly, their design has an important influence on overall weight, power conversion efficiency, and cost. Because of the independence and interaction of parameters, judicious tradeoffs are necessary to achieve design optimization. A transformer can be designed to step voltage up or down the voltage. The transformer windings are enamel coated magnet wire which is wrapped around the core (as seen below). The number of windings is determined by the number of times that a piece of wire makes a complete turn around the core. The primary winding is the winding which is driven (in car audio amplifiers, it's usually driven by transistors). The secondary winding is the output winding. The secondary is driven by the magnetic field that the primary induces in the core. A transformer with a ratio of 1:1 will not cause a voltage increase or decrease (disregarding small losses) from the primary to the secondary (as measured across each of the individual windings). If the ratio is 1:2 (primary: secondary), the voltage across the secondary will be twice the voltage across the primary. A ratio of 1:3 will result in a secondary voltage 3 times as high as the voltage on the primary. Of course all of this applies to a transformer which is very lightly or not loaded ( minimal current flow). When current is drawn from the secondary winding, there may (will) be a voltage drop and therefore a primary to secondary voltage ratio which may not match the winding ratio exactly. This loss of voltage is primarily due to the less than 100% efficiency of the magnetic coupling of the primary and the secondary windings through the core and also some copper (resistance) losses. Remember that the primary and the secondary windings are not generally electrically connected together. This means that all of the power transfer between the primary and secondary is transferred (magnetically) through the core. The general procedure for designing a transformer is given below Understand the terminology Understand the transformer equivalent circuit Write down requirements Select a core size Compute primary turns Compute secondary turns Fit wire to core window Compute leakage inductance 26

If interleaving factor (Fh) is OK, go build it. Otherwise, select new interleaves and go back to fitting wire. Obtain materials Wind the coils s Stack the laminations Test the performance If result is OK, you've done. Otherwise, go back and select a new (probably bigger) core size and loop back through the process.

Specifications:
Output voltage, Vo Output current, I o Operating frequency, f Efficiency, Flux Density, B = = = = = 5V 0.75 A 100 K 98% 0.15 T

Output Power P :
o

Po =V I o [W ]
V =Vo +Vd

V = 5 +1 = 6
Po = 6 0.75

P o = 4.5

[W ]

Apparent Power P :
t

27

 2 Pt = Po + 2 [W ] 2 Pt = 4.5 0.98 + 2

Pt 4.6

[W ]

( x)

Area Product A :
p

Pt 104 Ap = K B f K K m u j f

[cm ]
4

4.6 10 4 Ap = 4 0.2 100 0.4 403 Ap =1.89

( 0.12 )

[cm ]
4

For the area product of 1.89 cm 4 , core chosen is 55071 and the appropriate data for this core is Area product A p Inner dia i.d Outer dia o.d Core area Ac Surface area At = = = = = 1.863 cm 4 1.879

cm cm

4.367 48.0 8.15 4.68

0.672 cm 2
cm 2

Magnetic path length MPL = Mean length per turn MLT =

cm cm

Number of primary turns N :

p

Np =
Np =

V p 10 4 K f Bm f Ac
15 10 4 4 0.15 100 0.672

N p 4 [turns]

Number of Secondary turns N :

s

Ns =

Vs Np Vp

28

Ns =

5 4 15

N s = 1.3 2 [turns]

Primary Current I :
p

Ip =
Ip =

Po V p
4.5 15 0.98

I p = 0.306

[ A]

Current Density J :
J = K j A(py )
J = 403 1.863( 0.12 )

J = 374.0

[ A / cm ]
2

Bare wire size A

w( B )

:
Aw( B ) =
Aw ( B ) =

I p 0.707 J
0.3 0.707 374

Aw( B ) = 56.7 10 3 cm 2

5.2 Design of Inductor:

Specifications:
Inductance, L dc current, I o Frequency, f Flux density, Bm Core material: MPP = = = =
420 H

1A
100 KHz
0.15T

29

Energy K :
2 L Io K= 2

K =

87.5 10 6 2 2 2

K =175

[W

S]

Area product A :
p

2 k 10 4 Ap = B K K u j m

( x)

2 175 10 6 10 4 Ap = 0.15 0.4 403

Ap = 0.110 cm 4

(1.14 )

For the area product of 0.11 cm 4 , core chosen is 55121 and the appropriate data for this core is Area product A p Inner dia i.d Outer dia o.d Core area Ac Surface area At = = = = = 0.123 cm 4 0.902

cm cm

2.247

0.192 cm 2 18.90 cm 2 4.11 2.65

Magnetic path length MPL = Mean length per turn MLT = Inductance for 1000 turns =

cm cm

35. 10 3 H

Number of turns N :
L N = 1000 L 1000

30

 420 10 3 N = 1000 35

N = 12 [turns]

Current Density J :
J = K j A(py )
J = 403 0.123( 0.12 )

J = 518.22 A / cm 2

Bare wire size A

w( B )

:
Aw( B ) =
Aw ( B ) =

Ip J

[cm ]
2

1 518.22

Aw ( B ) 2 10 3 cm 2

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