Magnetec: Advanced Softmagnetic Materials For Electromagnetic Compatibility - EMC

MAGNETEC
MAGNET-TECHNOLOGIE
Advanced softmagnetic materials for electromagnetic

compatibility – EMC
advanced softmagnetic materials for electromagnetic compatibility - EMC

© MAGNETEC GmbH, Langenselbold www.magnetec.de 05/2002 Dr. Fe 1/35
MAGNETEC
MAGNET-TECHNOLOGIE
- EMC/EMI basics
- mains filters and current compensated chokes
- comparison: nano and ferrite cores
- production process of nanocrystalline cores
Content of presentation
MAGNETEC
MAGNET-TECHNOLOGIE
electromagnetical compatibility (EMC)

can be described as a - required - state:
„ the ability of a device, to work satisfactory in its electromagnetical

surrounding, without generating disturbing noise, which could be
unacceptable for other devices.“
(EMV-Richtlinie 89/336/EWG bzw. EMVG)
Currently, the global electromagnetical background noise level

doubles every three years ! 1)
1) Schaffner EMV AG
EMC basics: definition of EMC

MAGNETEC
MAGNET-TECHNOLOGIE
Steep dU/dt switching edges of mircroprocessors or power

transistors (IGBT) or pulsed currents drawn from the mains
supply line of switched mode power supplies (SMPS) are the
main reason for the unwanted emsissions of discrete or
continuous RF energy.
Examples:
- digital telecommunication equipment (ISDN, GSM)
- electronical power supplies for lightening applications
- any kind of voltage converter using SMPS technology
- variable speed drives
- white goods with microprocessors and variable speed drives
EMC basics: sources of RF noise emissions

MAGNETEC
MAGNET-TECHNOLOGIE
Big rectifier smoothening

50 Hz- DC-
230V-
trafo output
mains
~ +
-
50-Hz-mains adaptor - no RF- noise level but huge & heavy
switch small
50 kHz- rectifier smooth. DC-
230V- EMI-
trafo output
mains filter
~ +
-
SMPS - EMI filter required, compact, light weight, highly efficient
Comparison: 50Hz vs. switched mode power supply

MAGNETEC
MAGNET-TECHNOLOGIE
50-Hz-technology
example: adaptor
Ps = 6 VA (12V / 0,5A)
m = 440g
η = 38 %
SMPS
example: notebook
Ps = 30VA (15V / 2A)
m = 220g
η up to 95 %
SMPS technology: significant reduction of size and weight

MAGNETEC
MAGNET-TECHNOLOGIE
radiated noise capacitive and conducted noise

distribution inductive coupling distribution
Is
RF source RF drain
emission Us immunity
radiation
noise current
Radiation E-field noise voltage
H-field
possible ways of distribution of RF noise
EMC basics: scenario

MAGNETEC
MAGNET-TECHNOLOGIE
variable speed drive (inverter) = source

asyn-
e.g. ~ dc-link PWM ~
rectifier DC DC chronous
ISA ~ inverter ~ motor
~
control circuit
70
60
70 variable
50
60 voltage &
frequency
Un o i s e [dBµV]
50
Un o i s e [dBµV]
40
40
30
30
20
20
10
10
0
1000 1000 frequency [kHz] 10000 100000
100 1000 frequency [kHz] 10000 100000
rf
EMC basics: inverter drive as rf-noise source

MAGNETEC
MAGNET-TECHNOLOGIE
typical voltage and 50µµs/unit

t t==50 s/unit
harmonics in a variable
250µµss
TT==250
speed drive (inverter) –
used in many future
PowerNet systems. Those
unwanted rf-signals are
distributed over all
connected wiring systems
fundamental wave 4 kHz
harmonics 00 20
20 40
40 60
60 80
80 100
100 kHz
kHz [f]
[f]
EMC basics: sources of RF noise emissions

MAGNETEC
MAGNET-TECHNOLOGIE
100
~ amount %
conducted
emission
50
⇒ filter
radiated
emission
⇒ shielding
0
1 kHz 10 100 1 MHz 10 100 1GHz
LW MW SW FM frequency f
typical distribution of emitted energy as a function of frequency
EMC basics: ways of distribution of RF noise

MAGNETEC
MAGNET-TECHNOLOGIE
Quasi Peak voltage U [dBµV] 100 1:100.000
class A industrial
80 1:10.000
60 1:1.000
class B domestic
40
150 kHz frequency 30 MHz
noise level-limits of EN 55011 (common mode, conducted, 50Ω-system)
EMC basics: RF noise level limits

MAGNETEC
MAGNET-TECHNOLOGIE
reference ground
test device artifical test receiver

mains
wooden
table
all values in cm
EMC basics: measurement setup for RF noise

MAGNETEC
MAGNET-TECHNOLOGIE
Us [dB µV] 80
60 poor filtering, limits
of EN55011, class B
40
are exceeded
20
0
0,1 1 10 f [MHz]
80
Us [dB µV]
60 appropriate filtering,
limits of EN55011,
40
class B are met
20
0
EMC basics: real noise level spectrum (quasi-peak)

MAGNETEC
MAGNET-TECHNOLOGIE
-Increasing number of unwanted RF-noise sources

resulting in a continuous increase of background level
- regulations will be getting more stringent
- regulations will be defined in new
- new regulations to come
- new noise sources will come
- contious increase of costs for filtering measures
- global introduction of emc regulations
EMC basics: future trends and outlook

MAGNETEC
MAGNET-TECHNOLOGIE
Filter
L1
Cx1 Cx2 Cy2
240V load
N R
mains
PE L Cy2
Cxn X-capacitor
Cyn Y-capacitor
L current compensated choke
R discharge resistor
basic circuitry of a EMI mains filter
EMC basics: mains filter

MAGNETEC
MAGNET-TECHNOLOGIE
EMI filters are commonly desinged as reflecting low-pass-filters

ausgelegt, this means, they work according to the principle of rf-mismatch.
Thus, a part of the high-frequency currents are ‚deviated‘ – the other part
will be aborped – e.g. in form of core losses and other mechanisms.
differential mode
noise source Cx1 Cx1 Cy2
noise
f < 500kHz of
drain
noise
Lstreu Cy2
Propagation of noise
currents
common mode source Cx1 Cx2 Cy2

noise noise
f > 500kHz of drain
noise LN Cy2
EMC basics: working principle of mains filters

MAGNETEC
MAGNET-TECHNOLOGIE
measuring generator
(150kHz-30MHz) measuring receiver
1:1 1:1 (selective voltmeter)
50 Ω test item 50 Ω
(filter)
U1 U2
U1
αe= 20 log [dB]
2 U2
conforming test setup of attenuation level αe
EMC basics: setup of attenuation level measurement

MAGNETEC
MAGNET-TECHNOLOGIE
Hload = 0
single phase version
HRF ≠ 0
RF current
load current
working principle of a current compensated choke for

attenuation of common mode RF noise three-phase version
EMC basics: principle of common mode chokes

MAGNETEC
MAGNET-TECHNOLOGIE
main requirements on a EMC filter choke:

high impedance (f = 150 kHz to 30 MHz)
Z(f) = ωL(f) = 2πf L(f)
L(f) = AL n2 mit AL = µ0 µr(f) Afe/lf
number of turns iron cross section

permeability !
EMC basics: choice of softmagnetic material

MAGNETEC
MAGNET-TECHNOLOGIE
Bs
Induktion B →
Br
Hc Hs
Feldstärke H →
Bs: saturation lux density (high!) Br: remanence (low!)

Hc: coercitivity field strength (low!) Hs: saturation field strength (high!)
Characteristics of softnagnetic alloys: Hysteresis loop

MAGNETEC
MAGNET-TECHNOLOGIE
- 1987: patent for a completely new softmagnetic material

with excellent properties by Yoshizawa, Oguma and
Yamauchi (Hitachi, Japan)
alloy composition: Fe73Cu1Nb3Si16B7
production process: rapid solidification
material structure: nanocrystalline; i.e. grain size 15 nm
- 1992: markt launch by VACUUMSCHMELZE
(VITROPERM®) and HITACHI Metals (FINEMET®)
- since 1995: introduction into several industrial applications
of power electronics and telecommunication
- 1999: 3. Source : MAGNETEC (NANOPERM®)
History of nanocrystalline alloys

MAGNETEC
MAGNET-TECHNOLOGIE
Alloy Permeability Saturation induction Curie-temp. max. working

µ‘ (10 / 100kHz) Bs [T] (25 / 100°C) Tc [°C] temp. Tmax [°C]
r
Ferrite 3E7 15.000 / 12.000 0,38 / 0,21 >130 95

Ferrite T38 10.000 / 10.000 0,38 / 0,23 >130 95
}
NANOPERM 100.000 / 20.000
80.000 / 28.000 1,2 / 1,18 600 120 (180)
30.000 / 20.000
NANOPERM vs. Ferrit:

- permeability - up to a factor of 10 (!)
- saturation induction - factor 3
- working temperature range - up to 180°C
- disadvantage: price ~ factor 1,5 - 2 (functional value)
⇒ advanced, smaller and lighter components ⇐
Comparison of materials
MAGNETEC
MAGNET-TECHNOLOGIE
1,5
NANOPERM
µ = 80.000
1,0 µ = 30.000
0,5
B [T]
0
Ferrite
-0,5 T 38
µ = 10.000
-1,0
f = 1 Hz
-1,5
-1000 - 500 0 H [mA/cm] 500 1000
hysteresis loops, saturation field as a function of permeability level
MAGNETEC
MAGNET-TECHNOLOGIE
50.000
max.
max.for
for
Ferrite:
permeabiliy @ 10kHz/3mA/cm
40.000 Ferrite:
about
about120°C
120°C
NANOPERM
30.000
20.000
Ferrite
10.000
0
-30 20 T [°C] 70 120 180
170
permeability
permeabilityas
asaafunction
functionof
oftemperature
temperature
MAGNETEC
MAGNET-TECHNOLOGIE
1,4
saturation induction Bsat [T]

1,2
NANOPERM
1
max.
max.for
for
0,8
Ferrite:
Ferrite:
0,6 Ferrite about
about120°C
120°C
N67
0,4
T38
0,2
0
0 100 200 T [°C] 300 400
saturation
saturationflux
fluxdensity
densityas
asaafunction
functionof
of temperature
temperatureTT
MAGNETEC
MAGNET-TECHNOLOGIE
60
NANOPERM
50
attenuation level [dB]
40
30
improved
improved
Ferrite
20 attenuation
attenuation
below
below
10 500
500kHz
kHz
0
0,01 0,1 1,0 10,0 100,0
frequency f (MHz)
typical
typicalimpedance
impedancecurve
curveatatsame
samecore
coregeometry
geometryØ=30mm,
Ø=30mm,22
22turns
turns
MAGNETEC
MAGNET-TECHNOLOGIE
20
volume
volume NANOPERM
∅ = 40 mm
reduction
reduction
>>50%
50%
impedance Z [kΩ]
12
Ferrite
∅ = 63 mm
10 100 f [kHz] 1.000 10.000 100.000
typical
typicalimpedance
impedancecurve
curvefor
fordifferent
differentcore
coregeometries
geometries
MAGNETEC
MAGNET-TECHNOLOGIE
120
100
Ferrite Ø: 63mm,
3x22 turns, m = 380g
noise level [dbµV] 80
60
40
20 NANOPERM Ø: 40 mm,
3x32 turns, m = 94g
0
0,1 1 10 100
frequency f [MHz]
achieving more stringent noise limits even at a smaller build volume
MAGNETEC
MAGNET-TECHNOLOGIE
NANOPERM-choke Ferrite-choke
volume
volumereduction
reduction60%
60% IN = 3 x 25A @ 40°C
IN = 3 x 25A @ 60°C
LN = 3 x 1,6 mH @ 10kHz weight
weightreduction
reduction65
65%% LN = 3 x 1,3 mH @ 10kHz
m = 120g m = 350g
59 mm 73 mm
25 mm 39 mm
Comparison of build volume Nano/Ferrite Chokes

MAGNETEC
MAGNET-TECHNOLOGIE
ribbon thickness ~20µm
melt, T= 1200°C
ceramik-
nozzle
Cu-wheel, T = 20°C
amorphous
© AMT ribbon v = 100km/h
principle of production process of rapidly quenched ribbons
MAGNETEC
MAGNET-TECHNOLOGIE
cutting of ribbons with high precision knives

MAGNETEC
MAGNET-TECHNOLOGIE
automatic winding process of tape wound cores

MAGNETEC
MAGNET-TECHNOLOGIE
300 cm
60 cm
furnace and batch of cores for magnetic-field treatment

MAGNETEC
MAGNET-TECHNOLOGIE
protective epoxy coating of tape wound cores

MAGNETEC
MAGNET-TECHNOLOGIE
tape wound
cores from
10 ... 200 mm ∅
single phase
EMC chokes
up to I = 60A
three phase
EMC chokes
up to I = 200A
160 mm
available nano products – core and choke types


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MAGNETEC

Advanced softmagnetic materials for electromagnetic

advanced softmagnetic materials for electromagnetic compatibility - EMC

electromagnetical compatibility (EMC)

„ the ability of a device, to work satisfactory in its electromagnetical

Currently, the global electromagnetical background noise level

EMC basics: definition of EMC

Steep dU/dt switching edges of mircroprocessors or power

EMC basics: sources of RF noise emissions

Big rectifier smoothening

50-Hz-mains adaptor - no RF- noise level but huge & heavy

SMPS - EMI filter required, compact, light weight, highly efficient

Comparison: 50Hz vs. switched mode power supply

SMPS technology: significant reduction of size and weight

radiated noise capacitive and conducted noise

possible ways of distribution of RF noise

EMC basics: scenario

variable speed drive (inverter) = source

EMC basics: inverter drive as rf-noise source

typical voltage and 50µµs/unit

fundamental wave 4 kHz

EMC basics: sources of RF noise emissions

typical distribution of emitted energy as a function of frequency

EMC basics: ways of distribution of RF noise

Quasi Peak voltage U [dBµV] 100 1:100.000

150 kHz frequency 30 MHz

noise level-limits of EN 55011 (common mode, conducted, 50Ω-system)

EMC basics: RF noise level limits

test device artifical test receiver

EMC basics: measurement setup for RF noise

EMC basics: real noise level spectrum (quasi-peak)

-Increasing number of unwanted RF-noise sources

EMC basics: future trends and outlook

basic circuitry of a EMI mains filter

EMC basics: mains filter

EMI filters are commonly desinged as reflecting low-pass-filters

common mode source Cx1 Cx2 Cy2

EMC basics: working principle of mains filters

conforming test setup of attenuation level αe

EMC basics: setup of attenuation level measurement

working principle of a current compensated choke for

EMC basics: principle of common mode chokes

main requirements on a EMC filter choke:

number of turns iron cross section

EMC basics: choice of softmagnetic material

Bs: saturation lux density (high!) Br: remanence (low!)

Characteristics of softnagnetic alloys: Hysteresis loop

- 1987: patent for a completely new softmagnetic material

History of nanocrystalline alloys

Alloy Permeability Saturation induction Curie-temp. max. working

Ferrite 3E7 15.000 / 12.000 0,38 / 0,21 >130 95

NANOPERM vs. Ferrit:

hysteresis loops, saturation field as a function of permeability level

saturation induction Bsat [T]

10 100 f [kHz] 1.000 10.000 100.000

achieving more stringent noise limits even at a smaller build volume

Comparison of build volume Nano/Ferrite Chokes

ribbon thickness ~20µm

cutting of ribbons with high precision knives

automatic winding process of tape wound cores

furnace and batch of cores for magnetic-field treatment

protective epoxy coating of tape wound cores

available nano products – core and choke types