CH 14 Slide

Chapter 14.
Transformer Design
Some more advanced design issues, not considered in previous

chapter:
n1 : n2
Inclusion of core loss

i1(t)
Selection of operating flux

density to optimize total loss
Multiple winding design: how
to allocate the available
window area among several
windings
v1(t)
v2(t)
R1
R2
+
A transformer design
procedure
ik(t)
vk(t)
How switching frequency

affects transformer size
Fundamentals of Power Electronics
i2(t)
: nk
Rk
Chapter 14: Transformer design
Chapter 14. Transformer Design
14.1. Winding area optimization

14.2. Transformer design: Basic constraints
14.3. A step-by-step transformer design procedure
14.4. Examples
14.5. Ac inductor design
14.6. Summary
14.1. Winding area optimization

Given: application with k windings
having known rms currents and
desired turns ratios
v1(t) v2(t)
n1 = n2 =
n1 : n2
rms current
rms current
I1
I2
v (t)
= nk
k
Core
Window area WA
rms current
Ik
Core mean length

per turn (MLT)
Wire resistivity
Fill factor Ku
: nk
Q: how should the window

area WA be allocated among
the windings?
Allocation of winding area

Winding 1 allocation
1WA
Winding 2 allocation
2WA
{
{
Total window
area WA
etc.
0 < j < 1
1 + 2 +
+ k = 1
Copper loss in winding j

Copper loss (not accounting for proximity loss) is
Pcu, j = I 2j R j
Resistance of winding j is
lj
Rj =
A W, j
with
Hence
l j = n j (MLT)
length of wire, winding j
WAK u j
A W, j =
nj
wire area, winding j
n 2j i 2j (MLT)
Pcu, j =
WAK u j
Total copper loss of transformer

Sum previous expression over all windings:
Pcu,tot = Pcu,1 + Pcu,2 +
(MLT)
+ Pcu,k =
WAK u
j=1
n 2j I 2j
j
Need to select values for 1, 2, , k such that the total copper loss
is minimized
Variation of copper losses with 1
cu,k
Copper
loss
For 1 = 0: wire of
winding 1 has zero area.
Pcu,1 tends to infinity
+..
.+
cu,
3
Pcu,tot
+
P cu,1
For 1 = 1: wires of
remaining windings have
zero area. Their copper
losses tend to infinity
u,
2
There is a choice of 1
that minimizes the total
copper loss
Pc
Method of Lagrange multipliers

to minimize total copper loss
Minimize the function
Pcu,tot = Pcu,1 + Pcu,2 +
(MLT)
+ Pcu,k =
WAK u
j=1
n 2j I 2j
j
subject to the constraint
1 + 2 +
+ k = 1
Define the function
f ( 1, 2,
, k, ) = Pcu,tot( 1, 2,
where
g( 1, 2,
, k) = 1
, k) + g( 1, 2,
, k)
j=1
is the constraint that must equal zero

and is the Lagrange multiplier
Lagrange multipliers
continued
Optimum point is solution of
the system of equations
Result:
(MLT)
=
WAK u
f ( 1, 2, , k,)
=0
1
f ( 1, 2, , k,)
=0
2
m =
j j
= Pcu,tot
nI
j j
An alternate form:
m =
V mI m
VI
n=1
j=1
n mI m
n=1
f ( 1, 2, , k,)
=0
k
f ( 1, 2, , k,)
=0
nI
k
j j
Interpretation of result
m =
V mI m
VI
n=1
j j
Apparent power in winding j is

V j Ij
where
Vj is the rms or peak applied voltage

Ij is the rms current
Window area should be allocated according to the apparent powers of

the windings
10
Example
PWM full-bridge transformer
i1(t)
n1 turns
i2(t)
}
}
n2 turns
n2 turns
n2
I
n1
i1(t)
i3(t)
Note that waveshapes

(and hence rms values)
of the primary and
secondary currents are
different
i2(t)
n2
I
n1
I
0.5I
0.5I
0
i3(t)
Treat as a threewinding transformer
0.5I
0.5I
0
0
11
DTs
Ts
Ts+DTs
2Ts
Expressions for RMS winding currents
I1 =
I2 = I3 =
1
2Ts
2T s
i 21(t)dt =
1
2Ts
2T s
0
n2
I
n1
i1(t)
n2
I D
n1
i 22(t)dt = 12 I 1 + D
i2(t)
n2
I
n1
I
0.5I
0.5I
see Appendix 1
0
i3(t)
I
0.5I
0.5I
0
0
12
DTs
Ts
Ts+DTs
2Ts
Allocation of window area:
m =
V mI m
VI
n=1
j j
Plug in rms current expressions. Result:
1 =
1+
1
1+D
D
1
2 = 3 = 12
1+
Fraction of window area

allocated to primary
winding
D
1+D
13

allocated to each
secondary winding
Numerical example
Suppose that we decide to optimize the transformer design at the
worst-case operating point D = 0.75. Then we obtain
1 = 0.396
2 = 0.302
3 = 0.302
The total copper loss is then given by
(MLT) 3
Pcu,tot =
n jI j
WAK u j
=1
(MLT)n 22 I 2
=
1 + 2D + 2 D(1 + D)
WAK u
2
14
14.2 Transformer design:

Basic constraints
Core loss
Pfe = K feB max A cl m

Typical value of for ferrite materials: 2.6 or 2.7
Bmax is the peak value of the ac component of B(t)
So increasing Bmax causes core loss to increase rapidly
This is the first constraint
15
Flux density
Constraint #2
v1(t)
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:
1 =
area 1
t1
t2
t2
v1(t)dt
t1
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
1
Bmax =
2n 1A c
To attain a given flux density,

the primary turns should be
chosen according to
1
n1 =
2Bmax A c
16
Copper loss
Constraint #3
Allocate window area between windings in optimum manner, as
described in previous section
Total copper loss is then equal to
Pcu =
with
(MLT)n I
WAK u
2 2
1 tot
I tot =
j=1
nj
n1 I j
Eliminate n1, using result of previous slide:
21 I 2tot
Pcu =
Ku
(MLT)
WAA 2c
1
B 2max
Note that copper loss decreases rapidly as Bmax is increased
17
Total power loss

4. Ptot = Pcu + Pfe
Power
loss
Co
Ptot = Pfe + Pcu
fe
ss P
Co
ss P c
r lo
ppe
Ptot
re l
o
There is a value of Bmax

that minimizes the total
power loss
Pfe = K feB max A cl m

21 I 2tot
Pcu =
Ku
Optimum Bmax
(MLT)
WAA 2c
Bmax
1
B 2max
18
5. Find optimum flux density Bmax

Given that
Ptot = Pfe + Pcu

Then, at the Bmax that minimizes Ptot, we can write
dPfe
dPtot
dPcu
=
+
=0
d Bmax d Bmax d Bmax
Note: optimum does not necessarily occur where Pfe = Pcu. Rather, it
occurs where
dPfe
dPcu
=
dBmax
dBmax
19
Take derivatives of core and copper loss

Pfe = K feB
max
21 I 2tot
Pcu =
Ku
A cl m
dPfe
1
= K feB max
A cl m
dBmax
Now, substitute into
I
Bmax =
2K u
2 2
1 tot
(MLT)
WAA 2c
21 I 2tot
dPcu
=2
4K u
d Bmax
dPfe
dPcu
=
dBmax
dBmax
(MLT) 1
WAA 3c l m K fe
20
1
B 2max
(MLT) 3
B max
2
WAA c
and solve for Bmax:

1
+2
Optimum Bmax for a

given core and
application
Total loss
Substitute optimum Bmax into expressions for Pcu and Pfe. The total loss is:
Ptot = A cl mK fe
I
4K u
2 2
1 tot
2
+2
+2
(MLT)
WAA 2c
+2
+
2
2
+2
Rearrange as follows:
WA A c
2( 1)/
(MLT) l
2/
m
+2
Left side: terms depend on core

geometry
2
+2
+2
21I 2totK fe
2/
4K u Ptot
+ 2 /
Right side: terms depend on

specifications of the application
21
The core geometrical constant Kgfe

Define
K gfe =
WA A c
2( 1)/
(MLT) l m2/
+2
2
+2
+2
Design procedure: select a core that satisfies
K gfe
I K fe
2 2
1 tot
4K u Ptot
2/
+ 2 /
Appendix 2 lists the values of Kgfe for common ferrite cores

Kgfe is similar to the Kg geometrical constant used in Chapter 13:
Kg is used when Bmax is specified
Kgfe is used when Bmax is to be chosen to minimize total loss
22
14.3 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
1
(V-sec)
Allowed total power dissipation
Ptot
(W)
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
Bmax
23
(cm2)
(cm2)
(cm)
(cm)
(cm2)
(T)
Procedure
1.
Determine core size
21I 2totK fe
2/
K gfe
4K u Ptot
+ 2 /
10 8
Select a core from Appendix 2 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.
24
2.
Evaluate peak ac flux density

1
+2
2 2
8
1I tot (MLT)
1
Bmax = 10
2K u WAA 3c l m K fe
At this point, one should check whether the saturation flux densityis
exceeded. If the core operates with a flux dc bias Bdc, then Bmax + Bdc
should be less than the saturation flux density.
If the core will saturate, then there are two choices:
Specify Bmax using the Kg method of Chapter 13, or
Choose a core material having greater core loss, then repeat
steps 1 and 2
25
3. and 4.
Primary turns:
n1 =
Evaluate turns
1
10 4
2Bmax A c
Choose secondary turns according to

desired turns ratios:
n2 = n1
n2
n1
n3 = n1
n3
n1
26
5. and 6.
Choose wire sizes

assigned to each winding:
Choose wire sizes according

to:
n 1I 1
1 =
n 1I tot
n 2I 2
2 =
n 1I tot
1K uWA
n1
2K uWA
A w2
n2
A w1
n kI k
k =
n 1I tot
27
Check: computed transformer model

Predicted magnetizing
inductance, referred to primary:
n1 : n2
i1(t)
n A c
LM =
lm
2
1
iM(t)
i2(t)
LM
Peak magnetizing current:
R1
1
i M, pk =
2L M
R2
ik(t)
Predicted winding resistances:
n 1(MLT)
A w1
n (MLT)
R2 = 2
A w2
R1 =
: nk
28
Rk
14.4.1
Example 1: Single-output isolated

Cuk converter
Ig
4A
+ vC1(t)
vC2(t) +
25 V
20 A
Vg
v1(t)
v2(t)
V
5V
i1(t)
n:1
i2(t)
100 W
fs = 200 kHz
D = 0.5
n=5
Ku = 0.5
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
29
Waveforms
v1(t)
VC1
Area 1
Applied primary voltseconds:

1 = DTsVc1 = (0.5) (5 sec ) (25 V)
= 62.5 Vsec
D'Ts
DTs
i1(t)
nVC2
Applied primary rms

current:
I/n
I1 =
Ig
i2(t)
+ D' I g
=4A
Applied secondary rms

current:
I 2 = nI 1 = 20 A
Total rms winding

current:
I tot = I 1 + 1n I 2 = 8 A
nIg
D nI
30
Choose core size

(1.72410 6)(62.510 6) 2(8) 2(24.7) 2/2.6
8
K gfe
10
4 (0.5) (0.25) 4.6/2.6
= 0.00295
Pot core data of Appendix 2 lists 2213 pot core with
Kgfe = 0.0049
Next smaller pot core is not large enough.
31
Evaluate peak ac flux density

1/4.6
(1.72410 6)(62.510 6) 2(8) 2

(4.42)
1
Bmax = 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 Bmax in the vicinity of 0.1 T are typical for ferrite
designs that operate at frequencies in the vicinity of 100 kHz.
32
Evaluate turns
6
(62.510
)
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.
33
Determine wire sizes

Fraction of window area allocated to each winding:
1 =
2 =
4A
8A
1
5
(Since, in this example, the ratio of

winding rms currents is equal to the
turns ratio, equal areas are
allocated to each winding)
= 0.5
20 A
8A
= 0.5
From wire table,

Appendix 2:
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 =
34
AWG #16
AWG #9
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
35
Effect of switching frequency on transformer size

for this P-material Cuk converter example
4226
0.1
2616
2616
2213
2213
1811
0.08
0.06
1811
0.04
Bmax , Tesla
Pot core size
3622
0.02
0
25 kHz
50 kHz
100 kHz
200 kHz
250 kHz
400 kHz
500 kHz
1000 kHz
Switching frequency
As switching frequency is
increased from 25 kHz to
250 kHz, core size is
dramatically reduced
As switching frequency is
increased from 400 kHz to
1 MHz, core size
increases
36
14.4.2
Example 2
Multiple-Output Full-Bridge Buck Converter
Q1
D1
Q3
T1
D3
n1 :
I5V
: n2
160 V
100 A
D5
+
Vg
i2a(t)
i1(t) v1(t)
5V
Q2
D2
Q4
Switching frequency
D6
i2b(t)
: n2
D4
I15V
: n3
i3a(t)
D7
150 kHz
15 A
15 V
Transformer frequency
75 kHz
D8
Turns ratio
110:5:15
Optimize transformer at
D = 0.75
i2b(t)
: n3
37
Other transformer design details

Use Magnetics, Inc. ferrite P material. Loss parameters at 75 kHz:
Kfe = 7.6 W/Tcm3
= 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
(approximately 0.5% of total output power)
Use copper wire, with

= 1.72410-6 -cm
38
Applied transformer waveforms

v1(t)
T1
D3
n1 :
: n2
i2a(t)
D5
Vg
i1(t) v1(t)
n
n2
I 5V + 3 I 15V
n1
n1
i1(t)
D4
Area 1
= Vg DTs
Vg
D6
i2b(t)
: n2
: n3
i3a(t)
D7
i2a(t)
n2
n
I 5V + 3 I 15V
n1
n1
I5V
0.5I5V
0
D8
i2b(t)
i3a(t)
I15V
0.5I15V
: n3
0
0
DTs
39
Ts
Ts+DTs 2Ts
Applied primary volt-seconds

v1(t)
Vg
Area 1
= Vg DTs
0
0
Vg
1 = DTsVg = (0.75) (6.67 sec ) (160 V) = 800 Vsec
40
Applied primary rms current

i1(t)
n
n2
I 5V + 3 I 15V
n1
n1
n2
n
I 5V + 3 I 15V
n1
n1
n2
n3
I 1 = n I 5V + n I 15V
1
1
41
D = 5.7 A
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 = 12 I 5V 1 + D = 66.1 A
I 3 = 12 I 15V 1 + D = 9.9 A
42
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
43
Select core size

(1.72410 6)(80010 6) 2(14.4) 2(7.6) 2/2.6
8
K gfe
10
4 (0.25) (4) 4.6/2.6
= 0.00937
A2.2
EE core data
From Appendix 2
Core
type
Geometrical
constant
Geometrical
constant
(A)
(mm)
Kg
cm5
Kgfe
cmx
Crosssectional
area
Ac
(cm2)
Bobbin
winding
area
WA
(cm2)
Mean
length
per turn
MLT
(cm)
Magnetic
path
length
lm
(cm)
Core
weight
(g)
EE22
8.2610-3
1.810-3
0.41
0.196
3.99
3.96
8.81
EE30
-3
85.710
6.710
-3
1.09
0.476
6.60
5.77
32.4
EE40
0.209
11.810-3
1.27
1.10
8.50
7.70
50.3
EE50
0.909
28.410-3
2.26
1.78
10.0
9.58
116
44
Evaluate ac flux density Bmax

Eq. (14.41):
2 2
8
1I tot (MLT)
1
Bmax = 10
2K u WAA 3c l m K fe
1
+2
Plug in values:
1/4.6
(1.72410 6)(80010 6) 2(14.4) 2

(8.5)
1
Bmax = 10
2 (0.25)
(1.1)(1.27) 3(7.7) (2.6)(7.6)
8
= 0.23 Tesla
This is less than the saturation flux density of approximately 0.35 T
45
Evaluate turns
Choose n1 according to Eq. (14.42):
n1 =
1
10 4
2Bmax A c
To obtain desired turns ratio

of
(80010 6)
n 1 = 10
2(0.23)(1.27)
= 13.7 turns
4
110:5:15
we might round the actual
turns to
Choose secondary turns

according to desired turns ratios:
22:1:3
Increased n1 would lead to
5
n2 =
n = 0.62 turns
110 1
Less core loss

More copper loss
15
n = 1.87 turns
n3 =
110 1
Rounding the number of turns
Increased total loss

46
Loss calculation
with rounded turns
With n1 = 22, the flux density will be reduced to
(80010 6)
Bmax =
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
8
1
Pcu =
10
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.
47
Calculations with EE50

Repeat previous calculations for EE50 core size. Results:
Bmax = 0.14 T, n1 = 12, Ptot = 2.3 W
Again round n1 to 22. Then
Bmax = 0.08 T, Pcu = 3.89 W, Pfe = 0.23 W, Ptot = 4.12 W
Which is close enough to 4 W.
48
Wire sizes for EE50 design

Window allocations
1 =
I1
= 5.7 = 0.396
I tot 14.4
2 =
n 2I 2
= 5 66.1 = 0.209
n 1I tot 110 14.4
3 =
n 3I 3
= 15 9.9 = 0.094
n 1I tot 110 14.4
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)
A w3 = 3 u A =
= 13.910 3 cm 2
(3)
n3
AWG #16
Might actually use foil or Litz wire for secondary windings
49

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Chapter 14.

Some more advanced design issues, not considered in previous

Inclusion of core loss

Selection of operating flux

How switching frequency

Fundamentals of Power Electronics

Chapter 14: Transformer design

Chapter 14. Transformer Design

14.1. Winding area optimization

Fundamentals of Power Electronics

Chapter 14: Transformer design

14.1. Winding area optimization

Core mean length

Fundamentals of Power Electronics

Q: how should the window

Allocation of winding area

Fundamentals of Power Electronics

Chapter 14: Transformer design

Copper loss in winding j

length of wire, winding j

wire area, winding j

Fundamentals of Power Electronics

Chapter 14: Transformer design

Total copper loss of transformer

Pcu,tot = Pcu,1 + Pcu,2 +

Fundamentals of Power Electronics

Chapter 14: Transformer design

Variation of copper losses with 1

Fundamentals of Power Electronics

Chapter 14: Transformer design

Method of Lagrange multipliers

Pcu,tot = Pcu,1 + Pcu,2 +

subject to the constraint

Define the function

is the constraint that must equal zero

Chapter 14: Transformer design

Fundamentals of Power Electronics

Chapter 14: Transformer design

Apparent power in winding j is

Vj is the rms or peak applied voltage

Window area should be allocated according to the apparent powers of

Fundamentals of Power Electronics

Chapter 14: Transformer design

Note that waveshapes

Treat as a threewinding transformer

Fundamentals of Power Electronics

Chapter 14: Transformer design

Expressions for RMS winding currents

Fundamentals of Power Electronics

Chapter 14: Transformer design

Allocation of window area:

Plug in rms current expressions. Result:

Fundamentals of Power Electronics

Fraction of window area

Fraction of window area

Chapter 14: Transformer design

Fundamentals of Power Electronics

Chapter 14: Transformer design

14.2 Transformer design:

Pfe = K feB max A cl m

This is the first constraint

Fundamentals of Power Electronics

Chapter 14: Transformer design