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Ac inductor
Conventional transformer
Coupled inductor
Flyback transformer
SEPIC transformer
Magnetic amplifier
Saturable reactor
Filter inductor
CCM buck example
B
Bsat
i(t)
Hc
Hc0
i(t)
Hc
iL
B-H loop,
large excitation
0
DTs
Ts
i(t)
+
v(t)
n
turns
air gap
reluctance
Rg
Rc
n i(t)
(t)
Rg
Ac inductor
L
B
Bsat
i(t)
B-H loop, for
operation as
ac inductor
i(t)
Hc
Hc
Hc
Ac inductor, cont.
Core loss, copper loss, proximity loss are all significant
An air gap is employed
Flux density is chosen to reduce core loss
A high-frequency material (ferrite) must be employed
Conventional transformer
i1(t)
n1 : n2
i2(t)
imp(t)
v1(t)
Lmp
v2(t)
v1(t)
1
2n 1A c
area 1
n 1i mp
lm
Hc
imp(t)
imp
H(t) =
Fundamentals of Power Electronics
n imp(t)
lm
Coupled inductor
i1(t)
Two-output
forward converter
example
n1
i1
v1
vg
i1
I1
n2
turns
i2
i2(t)
i2
I2
B
minor B-H loop,
coupled inductor
Hc
v2
Hc0
Hc
B-H loop,
large excitation
10
n1 : n2
i1
i1,pk
i2
imp
Lmp
vg
v
i2(t)
imp(t)
i1,pk
Hc
n 1i 1,pk R c
l m R c+R g
11
12
Objective:
Design inductor having a given inductance L,
i(t)
R
Pcu = Irms2 R
13
cross-sectional
area Ac
i(t)
+
v(t)
n
turns
air gap
lg
R c = cA
c
c
l
R g = gA
0
c
Rc
n i(t)
(t)
Rg
For R
14
>>
R g:
ni R
ni = BA cR
lg
nI max = BmaxA cR g = Bmax
0
This is constraint #1. The turns ratio n and air gap length lg are
unknown.
15
This is constraint #2. The turns ratio n, core area Ac, and air gap
length lg are unknown.
16
core
Total area of
copper in window:
nA W
Area available for winding
conductors:
K uWA
Third design constraint:
K uWA nA W
17
18
R=
lb
AW
l b = n (MLT)
where (MLT) is the mean-length-per-turn of the winding. The meanlength-per-turn is a function of the core geometry. The above
equations can be combined to obtain the fourth constraint:
n (MLT)
R=
AW
Fundamentals of Power Electronics
19
nI max = Bmax
0 A cn 2
L=
lg
lg
0
K uWA nA W
n (MLT)
R=
AW
20
L 2I 2max
A 2c WA
2
(MLT) B max RK u
Right-hand side: specifications or other known quantities
Left-hand side: function of only core geometry
So we must choose a core whose geometry satisfies the above
equation.
The core geometrical constant Kg is defined as
A 2c WA
Kg =
(MLT)
21
Discussion
L 2I 2max
A 2c WA
Kg =
2
(MLT) B max RK u
Kg is a figure-of-merit that describes the effective electrical size of magnetic
cores, in applications where the following quantities are specified:
Copper loss
Maximum flux density
How specifications affect the core size:
A smaller core can be used by increasing
Bmax use core material having higher Bsat
R allow more copper loss
How the core geometry affects electrical capabilities:
A larger Kg can be obtained by increase of
Ac more iron core material, or
WA larger window and more copper
Fundamentals of Power Electronics
22
(-cm)
Peak winding current
Imax
(A)
Inductance
L
(H)
Winding resistance
R
()
Winding fill factor
Ku
Core maximum flux density Bmax
(T)
The core dimensions are expressed in cm:
Core cross-sectional area
Ac
(cm2)
(cm2)
Core window area
WA
Mean length per turn
MLT
(cm)
The use of centimeters rather than meters requires that appropriate
factors be added to the design equations.
23
(cm 5)
24
(m)
25
AL
Core manufacturers sell gapped cores. Rather than specifying the air
gap length, the equivalent quantity AL is used.
AL is equal to the inductance, in mH, obtained with a winding of 1000
turns.
When AL is specified, it is the core manufacturers responsibility to
obtain the correct gap length.
The required AL is given by:
AL =
2
2
max c
2
max
10B
LI
L = A L n 2 10 9
(mH/1000 turns)
Units:
Ac
cm2,
L
Henries,
Bmax Tesla.
(Henries)
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LI max
n=
10 4
Bmax A c
27
K uW A
n
(cm 2)
Select wire with bare copper area AW less than or equal to this value.
An American Wire Gauge table is included in Appendix 2.
As a check, the winding resistance can be computed:
n (MLT)
R=
Aw
28
()
2.
29