DESIGN OF INDUCTOR

FILTER DESIGN:
INVERTER LC FILTER
SWITCHING FRREQUENCY = 5KHz
OUTPUT CURRENT

= 10A RMS

LINE VOLTAGE

= 230V RMS

LINE FREQUENCY

= 50Hz

CAPACITANCE VALUE CALCUALATED = 10uF, 600V

INDUCTANCE VALUE CALCULATED

= 4.5mH

INDUCTANCE DESIGN PROCEDURE

Several factors need to be considered while designing an inductor, few of which are listed
below
1.

Frequency of Operation

2.

Core Material Selection

3.

Energy Handling Capability of the Inductor (determines the size of the core)

4.

Calculate Number of Turn

5.

Selection of Copper wire

6.

Estimation of Losses and Temperature Rise

In this application the Inductor has to handle large energy due to the RMS current is 10A
maximum. At this current most of the ferrite core shapes does not support the design
(computed from the Area Product). So we select Iron powder core for this design.

The design of the ac inductor requires the calculation of the volt-amp (VA) capability. In this
applications the inductance value is specified.

Relationship of, Area Product Ap, to the Inductor Volt-Amp Capability

The volt-amp capability of a core is related to its area product, Ap, by the equation that may
be stated as Follows.

From the above, it can be seen that factors such as flux density, Bac, the window utilization
factor, Ku (which defines the maximum space occupied by the copper in the window), and
the current density, J, all have an influence on the inductor area product, Ap.

Fundamental Considerations
The design of a linear ac inductor depends upon five related factors:
1 . Desired inductance
2. Applied voltage, (across inductor)
3. Frequency
4. Operating Flux density which will not saturate the core
5. Temperature Rise

The inductance of an iron-core inductor, with an air gap, may be expressed as:

Final determination of the air gap requires consideration of the effect of fringing flux, which is
a function of gap dimension, the shape of the pole faces, and the shape, si/e, and location of
the winding

Fringing flux decreases the total reluctance of the magnetic path, and therefore increases
the inductance by a factor, F, to a value greater than that calculated from Equation

Where G is winding length of the core

Now that the fringing flux, F, has been calculated, it is necessary to recalculate the number
of turns using the fringing flux, Factor F

with the new turns, N(new), and solve for Bac

The losses in an ac inductor are made up of three components:

1. Copper loss, Pcu
2. Iron loss, Pfe
3. Gap loss, Pg

The copper loss, Pcu, is I2R and is straightforward, if the skin effect is minimal. The iron
loss, Pfe, is calculated from core manufacturers' data. Gap loss, Pg, is independent of core
material strip thickness and permeability.

INDUCTOR DESIGN STEPS

1 Design Spec
a
Inductance
b
Line Current
c
Line Frequency
d
Current Density
e
Efficiency goal

VL
L
IL
f
J
ef

Material
Magnetic

g
h
i

permiability
Flux Density
Window Utilisation

um
Bac
Ku

Temp Rise Goal

Tr

230
0.045
10
50
300
90

H
A
Hz
A/cm2
%

Iron Powder

Calculate Apparent power

2 Pt
Pt = VA = VL*IL

1200
1.4 Tesla
0.4
60 C

2300 A

3 Calculate Area Product

AP = VA*10^4/
AP
(4.44*Ku*f*Bac*J)

616.688116
7 cm4

4 Select Core
Iron Powder Core EI228
core Material
Magnetic Path Length
Mean Length Turn
Iron
Area
Window Area
Area product
coef
Surface Area
Material P
Winding Length
Lamination E

MPL
MLT
Ac
Wa
Ap
Kg
At
P
G

5 Calculate Number of Turns

6 Inductance Required

34.3 cm
2844 g
32.7 cm
31.028
24.496
760.064
288.936
1078

cm2
cm2
cm4
cm5
cm2

8.573
5.715
238.502559 turns

0.045 H

2.8KG + winding weight

7 Calculate required airgap

lg = (0.4piN2Ac10-4/L) (MPL/um)

8 Calculate Fringing flux F

Calculate New number of

9 turns
N1=sqrt(lg*L/0.4piACF108)
10 Calculate flux density
Bac = VL*10^4/
(4.44*N1*Ac*f

lg
lg

0.46404228
7 cm

1.30069975
1

N1
202.966702
7 turns

Bac

1.64511507
6 Tesla

11 Calculate Bare wire area

Awl

0.03333333
3 cm2

Awl=IL/J

12 Select wire from Wire table

AWG
14

Aw
uOhm/c
m

0.02 cm2
uOhm/c
82.8 m

Calculate Winding
13 Resistance
R

0.54954452
6 Ohms

PL

54.9544525
6 W

Calculate Watts per

15 kilogram
W/K =
0.000557*f^1.68*B^1.86

w/k

1.36544553
3 Ohm

16 Calculate Core Loss

Pfe =w/k *Wtfe

Pfe

0.92304118 W

R=MLT*N1*uOHm*10-6
14 Calculate Copper Loss
PL = IL2 * RL

17 Calculate Gap Loss

4.64042
3 mm

203

Pg = Ki*E*lg*f*B2

Pg

55.6247484
8 W

PL

111.502242
2 W

18 Calculate Total Loss

sum of losses

19 Calculate surface area watt density

psi = PL/At

psi

0.10343436
2 watts per cm2

Tr

69.0757599
5

Calculate the Temperature

20 rise
Tr = 450*psi^0.826
Calculate Window
21 utilisation
Ku = N1*Aw/Wa

0.16571416 watt

INDUCTOR WINDING DETAILS

210
200

3
2
I

I
0 1

Inductor
Termination

Winding Arrangement

WINDING DETAILS
N
o.

Winding
no.

Terminals

No of turns

1&2

200

Tapping
3

210

Core Details : EI 225

Wire
gauge
SWG
14

Insulation between
winding Layers
Nil
(Varnishing Reqd)

Remarks

CORE DIMENSIONAL DETAILS

WIRE TABLE