ASpreadsheetBasedProcedurefor

DesigningNaturallyCooledMagnetic
Components

WilliamP.Robbins
Dept.ofElectricalandComputerEngineering
UniversityofMinnesota
May,2002

MagneticComponentDesignProblem
Challengeconversionofcomponentoperatingspecs
inconvertercircuitintomagneticcomponentdesign
parameters.
Goalsimple,easytouseprocedurethatproduces
componentdesignspecsthatresultinanacceptable
designhavingaminimumsize,weight,andcost.
Inductorelectrical(e.g.convertercircuit)
specifications.
InductancevalueL
InductorcurrentsratedpeakcurrentI,ratedrms
currentIrms,andrateddccurrent(ifany)Idc
Operatingfrequencyf.
Allowablepowerdissipationininductoror
equivalentlymaximumsurfacetemperatureofthe
inductorTsandmaximumambienttemperatureTa.
Transformerelectrical(convertercircuit)
specifications.
RatedrmsprimaryvoltageVpri
RatedrmsprimarycurrentIpri
TurnsratioNpri/Nsec
Operatingfrequencyf
Allowablepowerdissipationintransformer or
equivalentlymaximumtemperaturesTsandTa

Designprocedureoutputs.
Coregeometryandmaterial.
Coresize(Acore,Aw)
Numberofturnsinwindings.
ConductortypeandareaAcu.
Airgapsize(ifneeded).
Abilitytocomparetheperformanceofdifferent
coresandcorematerialsforthesamecomponent.
Impedimentstoasimpledesignprocedure.
1. DependenceofJrmsandBoncoresizebecauseof
lossesandmagneticsaturation.
2. Howtochoseacorefromawiderangeof
materialsandgeometries.
3. Howtodesignlowlosswindingsathigh
operatingfrequencies.
4. Longtediouscalculationsrequiredtocompare
performanceofdifferentcoresandmaterialsfor
thesamecomponent
Detailedconsiderationofcorelosses,winding
losses,highfrequencyeffects(skinandproximity
effects),heattransfermechanismsrequiredforgood
designprocedures.

ManualTransformerDesign:AreaProductMethod
Start

AssembledesigninputsandcomputerequiredVIrating
S=2VpriIpri

Assemble design inputs

Choosecoregeometry,corematerial,andwindingconductor
geometry.

Compute 2 Vpri I
pri

Determine core size using

assumed values of J and B

Use2VpriIpri=4.4fkcuJrmsBacAwAcoretofindtherequired
areaproductAwAcoreandthusthecoresize.
AssumeJrms=24A/mm2andBac=50100mT.

Design winding (A cu,pri , Npri ,

A cu,sec , N sec )

Completedesignoftransformerasindicated.
Set S maxto desired S

No

Check power dissipation

and surface temperature.
Excessive?.

Done

Select
larger
core size
Yes

Checkpowerdissipationandsurfacetemperatureusing
assumedvaluesofJrmsandBac.Ifdissipationor
temperatureareexcessive,selectalargercoresizeandrepeat
designstepsuntildissipation/temperatureareacceptable.

ManualInductorDesign:AreaProductMethod
Start
Assemble design inputs

AssembledesigninputsandcomputerequiredLI rmsIprating
Choosecoregeometry,corematerial,andwindingconductor
geometry.

Compute LI

I
rms p =
kcu J rmsB pA A c
w

UseLIrmsIp=kcuJrmsBacAwAcoretofindtherequiredarea
productAwAcoreandthusthecoresize.

Determine core size using

assumed values of J, B, k cu

AssumeJrms=24A/mm2andBac=50100mT.
Design winding (A , N)
cu

No

Check power dissipation

and surface temperature.
Excessive?.

Set airgap. Re-adjust A

and N if needed.

Select
larger
core size

Completedesignoftransformerasindicated.

Yes

Checkpowerdissipationandsurfacetemperatureusing
assumedvaluesofJrmsandBac.Ifdissipationor
temperatureareexcessive,selectalargercoresizeandrepeat
designstepsuntildissipation/temperatureareacceptable.
SetairgaptoachieveBpatIpandadjustAandNifneeded.

Done

CritiqueofAreaProductMethod
ProcedureignoresdependenceofJandBoncoresize.
AssumedvaluesofJandBaresmallerthannecessaryforcomponentswithsmallelectrical
ratings
andresultsinoverlylargecomponentsforthesmallelectricalratingsrange.
AssumedvaluesofJandBarelargerthanallowableforcomponentswithlargeelectricalratings
andresultsincomponentsthataretoosmallforthelargeelectricalratingrange.
Largenumberofcoresandcorematerialsavailablemakesitdifficultforinexperienceddesignersto
makeareasonablefirstchoiceofcoreandcorematerialforaparticularapplication.Resultsin
multiple
manualandtimeconsumingdesigniterations.
Comparisonofdesignsusingdifferentcoregeometriesandmaterials(highlydesirableifthesmallest
sizedcomponentistobefound)impractical.
Requiresdetailedinformationonallcoresandcorematerialsofinterestwhichmaybedifficultto
findinashorttime.
Requiresmanylengthymanual(andhenceerrorprone)calculations.
Manualareaproductprocedurebestsuitedforoneoffdesignsituationsorwhererapidconstruction
andtestingismoreimportantthancost,size,orweightconsiderations.

RelatingJandBtoCoreSizeQuantitatively
Assumesimplethermalmodeloftransformer(core+winding).
1. Lossesuniformlydistributedoverentiretransformervolume.Psp,core=Psp,winding=Psp
2.Nosignificanttemperaturegradientsintransformerinterior.TinteriorTsurface=Ts
TsTa
Psp=R

Psp,core=Psp=kcu

B
Bs
Minor
hystersis
loop

- Bs

Example:EcoreGeometricParameters

D
radius =
1
4 (E-F)

Ecoredimensions

WindingareaAw=2D(EF)/2=D(EF)

Twocorehalvesmakeupacomplete
doubleEcore.

Meanturnlengthlw=2(F+C)+0.5(EF).
Seefiguretoleft.

CorevolumeVm,coreareaAm,andmean
pathlengthlmgivenincorespecsheet.

WindingvolumeVw=Awlw

WindingvolumeVw,windingareaAw,and
meanturnlengthlwwithoutcoil
formergenerallynotgiven.

Windingparametersofcoilformersused
inspreadsheetwhereavailable.

Similarformulasforallcoresindatabase.

Example:EcoreTransformerSurfaceAreaAs
2B

1
(E-F)
2

As=surfaceareaof
assembledcoreplussurface
areaofwindingnotincluded
incoresurfacearea.

Coresurfacearea
=4AB+4BC+2AC

Surfaceareaofwindingnot
includedincoresurfacearea
=4E{0.5}(EF)+
4{2D(0.5)(EF)}
=2E(EF)+4D(EF)
=2(EF)(E+2D)

Rounded corners
ignored in surface
area estimate
1
(E-F)
2

As=4AB+4BC+2AC+
2(EF)(E+2D)

2D

SpreadsheetbasedInteractiveCoreDatabase
Spreadsheetoffersidealwaytocalculatecoreratingsandassociateddesignparameters.
Completeinformationoncoreparameters(dimensions,areas,thermalresistance,etc.)andferrite
materialparameters(coreloss)prestoredinspreadsheetforallcoreandmaterialtypesofinterest.
Userentersinputspecificationsfromconverterdesignrequirements.
Spreadsheetcalculatescapabilityofallcoresindatabaseanddisplayssmallestsizecoreofeach
type thatmeetstransformerVIorinductorLIrmsIpspecifications.
AlsocalculatesanddisplaysdesignoutputparametersincludingJrms,B,Acu,pri,Acu,sec,Npri,Nsec,
leakageinductance,andefficiencyoftransformerorequivalentparametersforinductor.
Multipleiterationsofcorematerialandwindingconductorchoicescanbequicklydonetoaidin
selectionofmostappropriatetranformer/inductordesign.
Graphicalcapabilitiesofspreadsheetallowgraphicaldatapresentationifdesired.
Abilitytocomparedifferentcoresandcorematerialsforsameapplicationlimitedonlybynumber
ofcoresandmaterialsenteredinthedatabase.

Example:PreStoredPotcoreParametersinDatabase
designation

Phillips
[mm]

[mm]

[mm]

[mm]

[mm]

[mm]

[mm]

[mm]

[mm]

[mm ]

[mm ]

[mm]

w/bobbin
2
[mm ]

[mm ]

[mm ]

w/bobbin

WindingwindowparametersLw,Aw,andVwbasedonuseofcoilformerorbobbin.

Eachcoregeometryhasaseparateworksheetsimilartothepotcoresheetshownabove.

Ecoress
ECcores
EFDcores
EPcores
EPcores
ERcores
ETDcores
PMcores
Potcores
PQcores
RMIcores
Ucores

FerriteMaterialsinSpreadsheetDatabase
Ferrite
MANUFACT.

Bsat
[mT @ 100 C]
370
350
300
360
310
320
340
380
340
330
340
320
350
350
310
320
310
330
330
330
350
310
180

330

Material

Parameters

SUGGESTED
MAX FREQ
[kHz]
1000
1000
2000
1000
3000
1000
1000
1000
1000
1000
1000
1000
1000
1000
100
1000
2000
1000
1000
2000
3000
5000
10000

C(T)
0.74353
0.62004
0.79307
1.058
1.01975
0.66403
1.04602
1.25767
1.1317
0.7942
1.2119
0.7098
1.19713
1.416
1.0033
0.6658
1.0999
1.1194
1.1423
0.9167
0.9678
0.8455
0.88

MATERIAL
SIEMENS
N27
N41
N49
N53
N59
N61
N62
N63
N67
N72
N87
PHILIPS
3B8
3C15
3C30
3C80
3C81
3C85
3C90
3C94
3F3
3F35
3F4
4F1

Kc

a/ o

2.1566E-05
1.66E-04
1.2322E-06
2.6E-06
5.66E-06
1.26E-05
9.92E-07
1.9E-06
9.8288E-07
6.20E-07
4.12E-07

1
1
1
1
1
1
1
1
1
1
1

2.34
1.98
2.89
2.666
2.7926
2.420
2.808
2.757
2.851
2.869
3.00

5000
4800
2100
4300
1700
3600
4600
4700
4300
4000
4600

7.10E-07
1.20E-07
4.25E-07
9.63E-06
7.99E-07
4.95E-07
5.60E-07
1.60E-07
1.38E-06
1.19E-08
1.73E-07
1.58E-05

1.6
1.7
1.5
1.42
1.56
1.6
1.5
1.6
1.3
1.5
1.35
1.35

2.5
2.8
2.7
2.2
2.55
2.6
2.6
2.7
2.5
3.52
3.11
2.25

4000
5000
5000
4000
5500
4000
5500
5500
4000
2500
1700
300

2.7

5500

Transfer

Data

21

1.5992E-07

1.6

DetailsofInteractiveTransformerCoreDatabaseCalculations
Userinputs:Vpri,Ipri,Vsecf,Ts,Ta,andkcufortransformer;L,Irms,Ip,f,Ts,Ta,andkcuforinductor.

Storedinformation(static,independentofconverterrequirements)
Coredimensions,Aw, Acore, Vc,Vw, surfacearea, meanturnlength,meanmagneticpathlength,etc.
Quantitativecorelossformulasforallmaterialsofinterestincludingapproximatetemperaturedependence.
Spreadsheetcalculatescapabilitiesofallcoresindatabase
1. ConverterrequiredtransformerVIrating=VpriIpriorinductorstoredenergyrating=LIrmsIp.
2. ComputeallowablespecificpowerdissipationPsp=[TsTa]/{Rsa[Vc+Vw]}.Rsa=h/As
3. ComputeallowablefluxdensityPsp=kfb[Bac]dandcurrentdensityPsp=kcucu{Jrms}2.
4. Computecorecapabilities4.4fkcuAw Acore Bac Jrms(transformer)orkcuAw Acore Bp Jrms(inductor)
Calculationoftransformerparameters.
1. NumberofprimaryturnsNpri=Vpri/{2fAcpreBac}andsecondaryturnsNsec=Vsec/{2fAcpreBac}
2. WindingconductorareasassuminglowfrequenciesoruseofLeitzwire
Acu,pri=[kcuAw]/[2Npri]andAcu,sec=[kcuAw]/[2Nsec]

DetailsofInteractiveTransformerCoreDatabaseCalculations(cont.)
.

3. LeakageinductanceLleak={o{Npri}2lwbw}/{3p2hw}(Ecoreformula):Similarformulasforothercores.

Calculationofinductorparameters
1. ConductorareaAcu=Irms/Jrms;numberofturnsN=kcuAw/Acu
2. SetairgaplengthsothatatIptotalfluxdensity=Bp.Assumeeffectivedimensionsofgapareaequal
dimensions
ofcoreplusg,wheregistheairgaplength.
Spreadsheetexaminescapabilitiesofallcoresanddisplaysthesmallestsizecoreofeachdifferentgeometrythat
meetstherequirementsontheinputoutputpage(INOUT)ofthespreadsheet.
Transformeroutputs:corenumber,currentandfluxdensities,totalvolume,conductorareas,numberofprimary
andsecondaryturns,leakageinductance,andefficiency(powerout)/(powerin).
Inductoroutputs:corenumber,currentandfluxdensities,totalvolume,conductorarea,numberofturns,and
airgaplength.

InputOutputSectionofInductorDesignTool
Design
Inputs

kcu
0.4

Ta (

Ts(C)

35

70

Freq.[kHz]
40

40

Material
3F3

Inductance
[H]
39

Idc
[A]
0.001
0

3F3

Iac(b-p)
[A]
6.700

Ipeak
[A]
6.701

Irms
[A]
3.868

LIpIrms
[milliJoules]
1.01

67
Trianglar
Waveform
Assumedfor
ACcurrent

DESIGN
OUTPUTS
Skin,Prox.

CoreType
Ecore
ECcore
EFDcore
EPcore
ERcore
ETDcore
PMcore
Potcore
PQcore
RMIcore
Ucore

Core#
E25/13/7
EC35
#N/A
#N/A
ER28L
ETD29
PM50/39
P30/19
PQ26/25
RM10/I
U20/16/7

LIp Irms
[milliJoules]
1.12
2.26
0.00
0.00
1.37
1.71
12.38
1.36
1.39
1.21
1.18

Jrms
[A/mm

3.55
3.28
#N/A
#N/A
2.27
3.10
2.33
2.57
2.41
3.51
3.32

Bpeak

Acu

[mT]

[#]

[mm ]

[mm ]

21.97
15.54
#N/A
#N/A
21.16
18.00
4.56
11.46
11.25
12.90
23.19

1.09
1.18
#N/A
#N/A
1.70
1.25
1.66
1.50
1.60
1.10
1.16

1.15
0.61
#N/A
#N/A
1.44
0.93
0.20
0.66
0.49
0.54
1.10

211.49
199.54
#N/A
#N/A
151.76
191.00
154.81
166.47
193.56
209.65
201.28

Airgap

Effects?

[cm ]

YES
YES
#N/A
#N/A
YES
YES
YES
YES
YES
YES
YES

Notes
Any row having multiple cell entries of #N/A indicates the core in
that row cannot meet the input specifications. Cell entries with
negative numbers or #NUM! Indicate numerical problems in the calculations
for that cell. Entries in such cells should be ignored but the rest of
the entries in that row are still reliable. Airgap calculations are

the most likely to have problems.

Vc+Vw

6.47
11.97
#N/A
#N/A
12.55
10.41
75.41
10.02
9.21
6.54
8.09

[mm]
0.37314377

InputOutputSectionofTransformerDesignTool
Design
Inputs
Throughput

kcu

Ta (C)

Ts (C)

Freq. [kHz]

Material

Vpri,rms

Vsec,rms

Isec,rms

Power

Ipri,rms

TypicalUserInteractionWithSpreadsheet
Start
Enter design inputs
into core database
Spreadsheetsdonottakeskineffectand
proximityeffectintoaccount.

Examine database
outputs & select core

UsercaneitheruseLeitzwireoruse
theiterativeconductorselectionprocess
describedinthetextbook.

Neglect skin,
proximity effects?
No

Yes

Iterative selection of
conductor type/size.

Select wires

Finish

OtherSuggestedUsesofSpreadsheets
Corecapabilityversusfrequencyatfixedtemperature.(Examplegivenonnextslide)
Corecapabilityversustemperatureatfixedfrequency.
Corecapabilityversussize(volumeorweight).
Materialperformancefactorsversusfrequency.(Examplegiveninfollowingslides.)
Effectofdifferentcorematerialsonaspecificcomponentdesign.
Spreadsheetgraphingcapabilitiesveryusefulforpresentingoutputdataincleargraphicalformat
insteadofhardertounderstandnumericaltables.Examplesgiveninnexttwoslides.
UsersfamiliarwithEXCELcaneasilymodifyspreadsheettoautomatecalculationssuchasthose
mentionedaboveaswellasothers.

Example:ECoreVACapabilityvsFrequency
CurvelabelsrefertoPhillipsEcoredesignations.
3C80ferrite;T=65C;kcu=0.2
10000

E80/38/20

9000
8000
7000
6000
5000
4000
3000
2000
1000
0

20

40

60

80

100

120

Example:SelectedMaterialPerformanceFactors
50
Experiment
Curvefit

45

40
4F1
35
3F4
30

25

20

15

N61

10
3C30

N41

0
10

100

1000

Frequency [kHz]

10000