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AN115
Designing a Continuous Current Buck-Boost Converter
Using a LPT E2000Q Core
By
Colonel Wm. T. McLyman
The principle behind flyback converters is based on the storage of energy in the inductor during the
charging, or on period, ton, and the discharge of energy to the load during the off period, toff.

Figure 1. Buck-Boost isolated, continuous, current converter.

Energy Transfer
In the continuous mode the energy, stored in the primary, is not completely transferred to the
secondary, and its circuits, during the off time, before another switching period occurs, as shown in
Figure 2. The continuous current B-H is shown in Figure 3.
Q1
2Vin
0

Ip
Q1

Q1
t

Vs
0

t
Is

CR 1

CR1
Io

0
ton

toff
T

I = 2Io(min)

Figure 2. Isolated, buck-boost, ideal voltage and current waveforms.

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B (tesla)

B
I
H

Bac = B/2

Continuous Current

Figure 3. B-H loop for the continuous current buck-boost converters.

When designing a LPT inductor, and after the core geometry (size) has been selected, then, the correct
core permeability can be calculated. Care must be used in selecting the right permeability so the core does
not saturate at the maximum amp-turns to which it will be subjected. The dc magnetizing curves for LPT
cores are shown in Figure 4. The permeabilities for LPT cores range from 60 to 500 perm. The engineer
will select a core with the highest permeability that will not saturate at maximum load current. This core
will produce an inductor with the smallest size.
110
100

Percent Permeability

LPT Cores
E 2000q

500

80
400
250

60

200
40

125
60

20
0
1

10
100
DC Magnetizing Force (Oersteds)

1000

Figure 4. DC magnetization curves for LPT cores.

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For a typical design example, assume a buck-boost converter, as shown in Figure 1, with the following
specifications:
Buck-Boost Isolated Continuous Current Design Specification
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.

Input voltage max ..........................................................................

Input voltage nom ..........................................................................
Input voltage min ...........................................................................
Output voltage ...............................................................................
Output current ...............................................................................
Output current ...............................................................................
Window utilization ........................................................................
Frequency .....................................................................................
Transformer efficiency ..................................................................
Maximum duty ratio.......................................................................
Regulation .....................................................................................
Operating flux density ...................................................................
Diode voltage ................................................................................
Temperature rise ...........................................................................

Vmax = 32 V
Vnom = 28 V
Vmin = 24 V
Vo = 5 V
Io = 10 A
Io(min) = 2 A
Ku = 0.4
f = 100 kHz
= 98 %
Dmax = 0.5
= 0.5 %
Bm = 0.8 T
Vd = 1.0 V
Tr = < 30C

Skin Effect
The skin effect on an inductor is the same as a transformer. The main difference is that the ac flux
is much lower and does not require the use of the same maximum wire size. The ac flux is caused
by the delta current, DI, and is normally only a fraction of the dc flux. In this design of a
continuous current buck-boost converter, both the dc current density and the high frequency ac
current density, will be calculated. In many cases, the ac current that is riding on top of the dc
current is small enough that it does not effect the overall current density of the single wire used.
There are times when the larger wire is just too difficult to wind. Large wire is not only hard to
handle, but it does not give the proper lay. It is easier to wind with bi-filar or quad-filar wire with
the equivalent cross-section.
Step No. 1. Calculate the total period, T.
1
T=
f
1
= 10[ s]
100000
Step No. 2. Calculate the maximum transistor on time, ton.
T=

ton = TDmax
ton = 10 106 0.5 = 5 [ s]
Step No. 3. Calculate the minimum duty ratio, Dmin.
Dmin =

Vmin
Dmax
Vmax

Dmin =

24
0.5 = 0.375
32
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Step No. 4. Calculate the secondary, maximum load power, Po(max).

Po( max ) = I o (Vo + Vd )
Po( max ) = 10 (5 + 1) =60 [W]
Step No. 5. Calculate the secondary, minimum load power, Po(min).
Po (min) = I o (min) (Vo + Vd )
Po (min) = 2 (5 + 1) =12 [W]
Step No. 6. Calculate the maximum, input current, I in(max) .
Po( max )
I in ( max ) =
Vmin
60
I in ( max ) =
= 2.55 [A]
24 0.98
Step No. 7. Calculate the minimum, input power, P in(min) .
Po

12
Pin ( min ) =
=12.2 [W]
0.98
Step No. 8. Calculate the required, primary inductance, Lp.
Pin ( min ) =

Lp

(V
=

Dmin ) T
2

in (max)

2 Pin (min)

32 0.3752 10 106
=59 [ H]
2 12.2
Step No. 9. Calculate the primary, delta current, I p.
Lp =

I p =

Dmax TVmin
Lp

0.5 10 106 24
=2.03 [A]
59 106
Step No. 10. Calculate the primary, delta rms current, I p(rms) .
I p =

I p ( rms ) = I p
I p ( rms ) = 2.03

ton
3T
5
=0.829 [A]
3 10

Step No. 11. Calculate the primary, peak current, Ipk

Po( max )
I in ( max ) =
Vmin
I in ( max ) =

60
= 2.55 [A]
24 0.98
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Step No. 12. Calculate the primary, rms current, Irms.

( I ) 2
I rms = I 2pk I pk I +
Dmax
3

2.032
I rms = 6.12 2 6.12 2.03 +
0.5 = 3.63 [A]
3

Step No. 13. Calculate the energy-handling capability in Watt-seconds, W-s.

Energy =

LI 2pk

2
59 106 6.12 2
Energy =
=0.0011 [W-s]
2
Step No. 14. Calculate the electrical conditions, Ke.
Ke = 0.145Po Bm2 x104
Ke = 0.145 60 0.82 104 = 0.000557
Step No. 15. Calculate the core geometry, Kg.
Kg =

( Energy )

K e

0.00112
=0.00435 [cm5 ]
0.00057 0.5
Step No. 16. Select, from the data sheet, a LPT core, comparable in core geometry, Kg.
Kg =

Core number...................................................................................... GC60112Q

Manufacturer .................................................................................... CMI
Magnetic path length ......................................................................... MPL = 5.11 cm
Core weight ...................................................................................... Wtfe = 9.5 g
Copper weight .................................................................................. Wtcu = 10.3 g
Mean length turn .............................................................................. MLT = 3.4 cm
Window Area ................................................................................... Wa = 0.849 cm2
Area Product .................................................................................... Ap = 0.204 cm4
Core geometry ................................................................................... Kg = 0.005938 cm5
Surface area ..................................................................................... At = 25.6 cm2
Core Permeability.............................................................................. = 250
Millihenrys per 1000 turns ................................................................ mH = 151
Step No. 17. Calculate the current density, J, using a window utilization Ku = 0.4.
J=

2 Energy 104
Ap Bm K u

J=

2 0.0011 104
=387 [A/cm2 ]
0.204 0.8 0.4
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Step No. 18. Calculate the required permeability, .
=

Bm MPL 104
0.4 Wa J Ku

0.8 5.11 104

= 248 use 250
0.4 3.14 0.849 387 0.4
Step No. 19. Calculate the number of turns, N.
=

L( new)

N = 1000

L(1000)

0.059
=19.8 use 20 [turns]
151
Step No. 20. Calculate the peak flux density, Bm.
N = 1000

Bm =

0.4 ( N ) ( I pk ) ( r ) x104

MPL
1.256 20 6.12 250 104
Bm =
= 0.752 [T]
5.11
Step No. 21. Calculate the primary wire area, A pw(B) , using a window utilization, Kpu = 0.2 .
Apw( B ) =

Wa K pu
Np

0.849 0.2
= 0.00849 [cm 2 ]
20
Step No. 22. Select a wire size with the required area from the wire Table. If the area is not within
10% of the required area, then, go to the next smallest size.
AWG = #18
Apw( B ) =

Aw( B ) = 0.00823 [cm2 ]

/ cm = 210
Step No. 23. Calculate the primary, current density, wire area, Jp.
Jp =

I prms
Apw( B )

3.63
=428 [A/cm2 ]
0.00849
Step No. 24. Calculate the skin depth, . The skin depth will be the radius of the wire.
6.62
=
f
Jp =

6.62
100 103

=0.0209 [cm]

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Step No. 25 Calculate the diameter of the primary wire, AWG 18, from Step 22.
4 AW ( B )
D=

4 0.00823
= 0.102 [cm]
3.14
Step No. 26. Subtract two times the skin depth, from the diameter, and calculate the new area.
Dn = D 2
D=

Dn = 0.102 2 0.0209 = 0.0602 [cm]

Dn2
4
3.14 0.06022
An =
= 0.00285 [cm 2 ]
4
Step No. 27. Take the difference between area, A w(B) , and the new area, An. This will be the area
An =

for the I current.

AI = Aw( B ) An
AI = 0.00823 0.00241 = 0.00402 [cm2 ]
Step No. 28. Calculate the primary delta current I p(rms) , current density, J.
J=

I p( rms )

AI
0.829
J=
= 206 [A/cm 2 ]
0.00402
I p(rms) current density J = 206 A / cm2
Idc current density J = 428 A / cm2
I p(rms) current density < Idc current density
Step No. 29. Calculate the primary, winding resistance, Rp.
6
R p = MLT N p
10
cm
R p = 3.4 20 210 106 =0.0143 [ ]
Step No. 30. Calculate the primary, copper loss, Pp.
Pp = I p2 ( rms ) R p
Pp = 3.632 0.0143 = 0.188 [W]

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Step No. 31. Calculate the secondary turns, Ns.
Ns =

N p (Vo + Vd ) (1 Dmax )
V p Dmax

20 (5 + 1) (1 0.5)
=5 [turns]
24 0.5
Step No. 32. Calculate the secondary inductance, Ls.
Ls = Ns2 ( LMT ) 109
Ns =

Ls = 52 151 109 =3.78 10-6 [H]

Step No. 33. Calculate the secondary, delta current, I .
I s =
I s =

(Vo + Vd ) T Dmin
Ls

( 5 + 1.0) 10 106 0.375

3.78 106
Step No. 34. Calculate the secondary, delta rms current, I
I s( rms ) = I p

= 5.95 [A]

p(rms)

T (1 Dmin )
3T

10 0.625
= 2.72 [A]
3 10
Step No. 35. Calculate the secondary, peak current, I s(pk) .
I s( rms ) = 5.95

I s ( pk ) =

Po
I
+
(Vo + Vd ) (1 Dmax ) 2

60
5.95
+
= 23 [A]
6.0 (1 0.5)
2
Step No. 36. Calculate the peak flux, density, Bm.
0.4 N p I pk 104
Bm =
MPL
1.256 20 6.12 250 104
Bm =
=0.752 [T]
5.11
Step No. 37. Calculate the secondary, rms current, I s(rms).
I s ( pk ) =

2
I 2
I s ( rms ) = I pk
I pk I +
3

(1 Dmin )

5.952
I s ( rms ) = 232 23 5.95 +
0.625=15.8 [A]
3

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Step No. 38 Calculate the secondary, wire area, A sw(B), using a window utilization, Ksu = 0.2 .
Asw( B ) =

Wa K su
Ns

Asw( B ) =

0.849 0.2
= 0.034 [cm 2 ]
5

Step No. 39 Select a wire size, with the required area, from the wire Table. If the area is not within
10% of the required area, then, go to the next smallest size.
AWG = #12
Asw = 0.0331 [cm2 ]
/ cm = 52.1
Step No. 40. Calculate the secondary I s(rms) , current density, wire area, Js.
Js =

I srms
Asw( B )

15.3
=477 [A/cm2 ]
0.0331
Step No. 41. Calculate the diameter of the secondary wire, AWG 12, from Step 39.
Js =

D=

4 Aw( B )

4 0.0331
=0.205 [cm]
3.1416
Step No. 42. Subtract two times the skin depth, from the diameter, and calculate the new area.
D=

Dn = D 2
Dn = 0.205 2 0.0209 = 0.163 [cm]
Dn2
4
3.14 0.1632
An =
= 0.209 [cm 2 ]
4
Step No. 43. Take the difference between area, A w(B) , and the new area, An. This will be the area
An =

for the I current.

AI = Aw( B ) An
AI = 0.034 0.0209 = 0.0131 [cm2 ]

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Step No. 44. Calculate the secondary delta current I s(rms) , current density, J.
J=

I s ( rms)
AI

2.72
= 208 [A/cm2 ]
0.0131
I s(rms) current density J = 208 A / cm2
J=

I dc current density J = 477 A / cm2

I s(rms) current density < I dc current density
Step No. 45. Calculate the winding resistance, Rs.
6
Rs = MLT N s
10
cm
Rs = 3.4 5 52.1 106 =0.000886 []
Step No. 46. Calculate the secondary, copper loss, Ps.
Ps = I s2 Rs
Ps = 15.82 0.000886 = 0.221 [W]
Step No. 47. Calculate the window utilization, Ku.
N A + N s Asw
Ku = p pw
Wa
20 0.00823 + 50.0331
= 0.389
0.849
Step No. 48. Calculate the total copper loss, Pcu.
Ku =

Pcu = Pp + Ps
Pcu = 0.188 + 0.221 = 0.409 [W]
Step No. 49. Calculate the regulation, , for this design.
Pcu
x100
Po
0.409
=
100 = 0.682 [%]
60
Step No. 50. Calculate the magnetizing force in oersteds, Oe.
0.4 N p I pk
H=
MPL
0.4 3.14 20 6.12
H=
=30.1 [Oe]
5.11
Now that the magnetizing force, H, has been calculated, the next step is to see if this magnetizing force
could saturate the core. In Figure 4, there is a curve for 250 perm material, located on the horizontal
axis of the 30 Oersteds mark. The next step is to see where the 30 oersteds intersect the 250 perm
curve. In this design, the inductor still has over 95% of its designed inductance.
=

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Step No. 51. Calculate the ac flux density in tesla, Bac.
I
0.4 N p r 104
2
Bac =
MPL
1.256 20 1.01 250 104
0.124 [T]
Bac =
5.11
Step No. 52. Calculate the watts per kilogram, WK.
WK = 8.64 107 f 1.834 Bac2.112
WK = 8.64 107 100,0001.834 0.1242.112 =15.6 [W/kg]
Step No. 53. Calculate the core loss, Pfe .
mW
Pfe =
Wtfe 103

g
Pfe = 15.6 9.5 103 =0.148 [W]
Step No. 54. Calculate the total loss P, core Pfe and copper Pcu, in Watts.
P = Pfe + Pcu
P = 0.148 + 0.409 = 0.557 [W]
Step No. 55. Calculate the watt density, .
P
=
At
0.557
=0.0217 [W/cm2 ]
=
25.6
Step No. 56. Calculate the temperature rise in degrees, C.
Tr = 450 0.826
Tr = 450 0.02170.826 =19 [C]
BIBLIOGRAPHY
1. Colonel William T. McLyman, Transformer and Inductor Design Handbook, Second Edition,
Marcel Dekker Inc., New York, 1988.
2. Colonel William T. McLyman, Magnetic Core Selection for Transformers and Inductors,
Second Edition, Marcel Dekker Inc., 1997.
3. Colonel William T. McLyman, Designing Magnetic Components for High Frequency, dc-dc
Converters, Kg Magnetics, Inc., 1993.
Software:
For information regarding the above Books and Companion Software for Windows 95', 98' and
NT, contact:
Kg Magnetics, Inc.
38 West Sierra Madre Blvd, Suite J
Sierra Madre, Ca. 91024
Phone: (626) 836-7233, FAX: (626) 836-7263
Web Page: www.kgmagnetics.com
Email: sheassoc@pacbell.net
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