Prof. S.

Ben-Yaakov , DC-DC Converters [3- 1]

Magnetics Design

3.1 Important magnetic equations

3.2 Magnetic losses
3.3 Transformer
3.3.1 Ideal transformer (voltages and currents)
3.3.2 Equivalent circuit of transformer
(coupling, magnetization current)
3.3.3 Design of transformer
3.4 Inductor design

Prof. S. Ben-Yaakov , DC-DC Converters [3- 2]

Faraday’s law
B
BDC
Ae Φ
H
HDC

dΦ dB ∆B
V =n = nA e ; µ=
dt dt ∆H
Φ - magnetic flux Weber [ Wb ] V - voltage [ V ]
Wb
B - flux density 2 = Tesla [ T ]
m
Also : Gauss [ G ] 1T = 10,000 G

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 Prof. S. Ben-Yaakov , DC-DC Converters [3- 3]

Ampere’s law

le H - magnetic field [ A/m ]

I
∫ Hdl = n ⋅ I
n
n ⋅I = H ⋅ le
n ⋅I
H= [ A/m ]
le

Prof. S. Ben-Yaakov , DC-DC Converters [3- 4]

Magnetic losses

B mW
P
BDC cm3
H
HDC

∆B

Magnetic losses ~∆B

“Good number” = 100mW/cm3 =100KW/m3

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 Prof. S. Ben-Yaakov , DC-DC Converters [3- 5]

Magnetic Losses

z “Good number”=100mW/cm3=100 kW/m3

Prof. S. Ben-Yaakov , DC-DC Converters [3- 6]

Magnetic losses

B mW
P
BDC cm3
H
HDC

∆B

Magnetic losses ~∆B

“Good number” = 100mW/cm3 =100KW/m3

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 Prof. S. Ben-Yaakov , DC-DC Converters [3- 7]

Magnetic Losses

Prof. S. Ben-Yaakov , DC-DC Converters [3- 8]

Magnetic Losses

z Curves for constant loss: 500mW/cm3

z Figure of merit B*f
z Each material has optimum operating temperature
(minimum loss)

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 Prof. S. Ben-Yaakov , DC-DC Converters [3- 9]

Transformer currents
I1 I2
I1 I2
n1 n2 n1 n2

I1 n2
For ideal transformer n1I1 = n2I2 =
I2 n1

At any given moment n1I1 = n2I2

I1,I2 opposite direction.

No magnetic energy stored due to useful
currents I1, I2 (they cancel each other)

Prof. S. Ben-Yaakov , DC-DC Converters [3- 10]

Transformer voltages

n1 n2
V1 V2

φ dφ1 dφ 2
V1 = n1 V2 = n2
dt dt
Assu min g φ1 = φ2
dφ1 dφ2
=
dt dt
V1 n1
=
V2 n2

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 Prof. S. Ben-Yaakov , DC-DC Converters [3- 11]

Voltages
Since each winding also represents an inductance,
therefore for any winding Vn = 0
Permissible voltages: AC only on any winding
V

A S1 S1 t
S2 S2
V
S1 S1
B t

S2 S2

C S1 S1 t
S2 S2

Prof. S. Ben-Yaakov , DC-DC Converters [3- 12]

Equivalent circuit (preliminary)

Ideal Ideal
Llkg1 Llkg1

Lm1 Lm2

1:n 1:n
Ideal
Llkg2 Lm2 = Lm1n2
Lm1
Ideal transformer L → ∞
1:n

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 Prof. S. Ben-Yaakov , DC-DC Converters [3- 13]

Leakage
z Leakage inductance z Leakage inductance is the
uncoupled magnetic flux
Lkg1 1:n Lkg2
I1 I2
n1
V1 V2
n2 Lm1

ideal

z Relationship between Llkg, M and k (coupling coefficient).

M = k L1 ⋅L 2
L lkg1 ≅ L m1(1 − k )
L lkg2 ≅ L lkg1 ⋅ n2

Prof. S. Ben-Yaakov , DC-DC Converters [3- 14]

Leakage
Llkg1 1:n Llkg2

Lm1 Vo

ideal
Vo
Llkg1 L'lkg2 Vo′ =
n2
L lkg2
Lm1 V'o L′lkg2 =
n2

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 Prof. S. Ben-Yaakov , DC-DC Converters [3- 15]

Magnetization Current

Vin
I1 Ideal Llkg2
t
I2 Vo
Vin Im
Vo R t
Lm1
I2
1:n t

Im
t

I1
t

Prof. S. Ben-Yaakov , DC-DC Converters [3- 16]

Transformer
B B sat+
I1 I2 B max+
n1
V1 V2
n2 ∆Β H
Bmax-
B sat-

1. Bmax ( could be symmetrical or asymmetrical )

2. Bmax < Bsat
3. In most case ( high frequency ) Bmax limit by magnetic
losses.
dΦ dB
V1 = n1 = n1A e
dt dt

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 Prof. S. Ben-Yaakov , DC-DC Converters [3- 17]

Symmetrical operation
V1 1
Vm B= ∫ Vdt
n1A e

t on Bmax + = Bmax −
Ts
B Vm t on
∆B = 2Bmax =
B max+ n1A e

{Vm ,ton }
n1 =
Bmax- 2Bmax A e
1
n1A e ~ t on t TS ~
on →
2 fs

Prof. S. Ben-Yaakov , DC-DC Converters [3- 18]

Skin effect

DC High Frequency

δ − skin depth
δ R AC 72
>1 δ (mm ) =
RDC f
f in Hz

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 Prof. S. Ben-Yaakov , DC-DC Converters [3- 19]

Skin Effect Solutions

Litz wire

Tape

Prof. S. Ben-Yaakov , DC-DC Converters [3- 20]

Proximity effect

Current crowding due to magnetic fields

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 Prof. S. Ben-Yaakov , DC-DC Converters [3- 21]

Aw
Aw =
[w A1 ⋅ n1 + w A 2 ⋅ n2 ]
k

k - filling factor k<1

I1 rms
w A1 =
J
Aw
wA J - current density A/m2
J ≅ 4.5 A/mm2

Aw - winding area n1
I2 = I1
n2

Prof. S. Ben-Yaakov , DC-DC Converters [3- 22]

Ap
n1I1rms JkA w
Aw = ⋅2 n1 =
Jk 2 ⋅ I1rms JkA w
=
{V1, t on }
n1 =
{V1, t on } I1rms ⋅ 2 2Bmax A e
2Bmax A e

Ap = A w Ae =
{V1, t on }2 ⋅ I1rms
{2Bmax }Jk
{V1, t on }2 ⋅ I1
Ap = rms

∆B ⋅ Jk
{V1,Don }2 ⋅ I1
Ap = rms

fs ⋅ ∆B ⋅ Jk

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 Prof. S. Ben-Yaakov , DC-DC Converters [3- 23]

Transformer design stages

{V1,Don }2 ⋅ I1
1. Calculate Ap Ap = rms

fs ⋅ ∆B ⋅ Jk

In symmetrical operation In asymmetrical operation

∆B = Bmax+ - Bmax- ∆B = Bmax - 0

2. Look for core

{Vm ,ton }
3. Calculate n1 by: n1 =
2Bmax A e
4. Calculate n2

Prof. S. Ben-Yaakov , DC-DC Converters [3- 24]

Inductor design

Need to store energy

I
( in transformer n1·I1= n2·I2 )

B
µ = µ oµr
µ µo - air (vacuum) permeability
H
µr - relative permeability

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 Prof. S. Ben-Yaakov , DC-DC Converters [3- 25]

Permeability
Henry
µo = 1.26·10-6 µr of ferrites ∼ 2000 - 4000
m
B = µH
B
Bo
µ r1
If µ is high B will reach
µr 2 quickly Bsat
H
Need to slower µ
Ho
µ r 2 < µ r1

Prof. S. Ben-Yaakov , DC-DC Converters [3- 26]

Gaps
Discrete Distributed
µo µr
air gap air gap
Φ

Same Φ magnetic lines in ferromagnetic material and in air.

l g << l e le
lg
lg + le ≅ le

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 Prof. S. Ben-Yaakov , DC-DC Converters [3- 27]

Current Crowding
Current crowding due to magnetic fields

RAC high around gap

Prof. S. Ben-Yaakov , DC-DC Converters [3- 28]

Inductance with Gap

l g << l e le
lg
lg + le ≅ le

Φ = constant B ≅ constant
B B
Hg = Hm = Bl e Bl g
µo µm Hl e = +
µm µo
nI = l eH = Hml e + Hgl g

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 Prof. S. Ben-Yaakov , DC-DC Converters [3- 29]

Inductance with Gap

Bl e Bl g
Hl e = +
µm µo
B
zDividing out le and defining µe =
H

B Bm Ba
H= = +
µ e µm l
µo e
lg

Prof. S. Ben-Yaakov , DC-DC Converters [3- 30]

Gap Calculation
 le 
1 1 1   + µrm
=
µ e µm
+
l  1  l g 
=
µo  e  µre l 
  µrm  e 
 lg  l 
 g
1 1 1
= + l 
µreµo µrmµo l  µrm  e 
µo  e  l 
  µre =  g
 lg   le 
1 1 1   + µrm
= +  
µre µrm  l e   lg 
 
  l 
 lg  le
If < µrm µre ≈  e 
lg  
 lg 

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 Prof. S. Ben-Yaakov , DC-DC Converters [3- 31]

Inductance
dI dΦ
V =L V =n
dt dt
dI dΦ
L =n
dt dt L-?

dΦ dB dH n dI
n = nA e = nA eµ = nA eµ
dt dt dt l e dt

dI n2 A eµ dI n2 A eµ
L = L=
dt l e dt le

Prof. S. Ben-Yaakov , DC-DC Converters [3- 32]

Two windings on same core

2
L1  n1 
= 
L 2  n2 

Inductor design
B
Bmax

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 Prof. S. Ben-Yaakov , DC-DC Converters [3- 33]

Saturation Limits
dI dΦ
L =n
dt dt
Ipk  dI  Bmax  dB 
L ∫   dt = nA e ∫   dt
0
 dt  0
 dt 
L Ipk = nAeBmax

LIpk
n= quick design and check
A eBmax

LIpk JkA w
Ae = n=
nBmax Irms

Prof. S. Ben-Yaakov , DC-DC Converters [3- 34]

Ap
LIpkIrms
Ap = A eA w =
Bmax Jk
LIpkIrms ≈ LI2

LI2
Energy stored =
2

Air gapped core Design

1. Calculate Ap
2. Choose a core
3. Iterate
4. Calculate l g ( or increase gap until L is as required )

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 Prof. S. Ben-Yaakov , DC-DC Converters [3- 35]

Cores
z Transformer core z Inductor core

air gap

Prof. S. Ben-Yaakov , DC-DC Converters [3- 36]

Cores

1. E - core

2. TOROID

3. ARENCO 4. POT

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 Prof. S. Ben-Yaakov , DC-DC Converters [3- 37]

Commercial cores

Prof. S. Ben-Yaakov , DC-DC Converters [3- 38]

Distributed gap core

zThe concept of AL

Hy Hy
AL = ( sometime )
turn 1000 turns
L for n turns: L = n2 ⋅ A L

Distributed
air gap

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 Prof. S. Ben-Yaakov , DC-DC Converters [3- 39]

AL

Prof. S. Ben-Yaakov , DC-DC Converters [3- 40]

Toroid Data

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 Prof. S. Ben-Yaakov , DC-DC Converters [3- 41]

Permeability change

1 Amp/m =79.5 Oe
L decreases with DC current !

Prof. S. Ben-Yaakov , DC-DC Converters [3- 42]

Losses

Misleading notations !
∆B NOT B

“Good number”=100mW/cm3

These curves are measured by feeding ac signals.

If the current is composed of DC + ripple, core loss is due
only to ripple component !
DC bias tend to increase loss

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 Prof. S. Ben-Yaakov , DC-DC Converters [3- 43]

Temp. Rize

z “Hot Spot” - Critical parameter

Prof. S. Ben-Yaakov , DC-DC Converters [3- 44]

Hanna Curve

LI pk
n= LI2 1
Ae Bmax H=
Ve Bmax
H LI pk
Hn = LI2
Ae Bmax HBmax =
Ve
nI LI
Hn = Bmax
le Ae Bmax = µ = µ rµ o
H

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 Prof. S. Ben-Yaakov , DC-DC Converters [3- 45]

Hanna Curve

Prof. S. Ben-Yaakov , DC-DC Converters [3- 46]

Core Size Selection

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 Prof. S. Ben-Yaakov , DC-DC Converters [3- 47]

Basic Design of Distributed Gap Core

1. Calculate LI2
2. Look up manufacturer data
3. Select Core
L
4. Calculate n = 1000
AL(1000)
5. Check Lmin
nI
6. Calculate losses. Temp rise and and µ = f ( )
le
7. Iterate

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