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Reproduced from
2012 Texas Instruments Power Supply Design Seminar
SEM2000, Topic 4
TI Literature Number: SLUP304
2012, 2013 Texas Instruments Incorporated
Power Seminar topics and online powertraining modules are available at:
ti.com/psds
I. Introduction
4-2
SLUP304
Topic 4
Magnetics design has always been somewhat of a mystery to many analog design engineers. In this paper,
I will attempt to demystify this by first discussing the foundational equations and conversion of units
necessary for magnetics design. I will give an in-depth example for a flyback-coupled inductor, showing
how to calculate inductance, wire gauge and AC/DC losses, flux density, core and bobbin fill factor, and
inductance rolloff. I will then discuss various core materials and how to get good coupling by properly
layering the primary and secondary windings on a bobbin.
Topic 4
Texas Instruments
4-3
SLUP304
Flux Density
Field Intensity
Permeability
Area
Length
B
H
Ae
l, lg
SI
Tesla
A-T/m
4 x 10-7
m2
m
CGS
Gauss
Oersteds
1
cm2
cm
CGS to SI
10-4
1,000/4
4 x 10-7
10-4
10-2
.4 N 2 (Ae) 10 9
Linductance =
le
lg +
Where:
Linductance = Henrys
= core permeability
N = number of turns
Ae = core cross-section (mm2)
le = core magnetic path length (mm)
lg = gap (mm)
(1)
(OD ID)
OD
ln
ID
(3)
Where:
OD = outside diameter of core (mm)
ID = inside diameter of core (mm)
N = number of turns
Ae = core cross-section (effective area) mm2
le = Mean magnetic path length (mm)
(2)
4-4
SLUP304
Topic 4
V. Core Geometry
IV. Inductance
The inductance of a wound core can be
calculated by the core geometry using Equation 1.
This equation is not in the SI or CGS systems. It
was derived using millimeters for dimensions,
which is what was given in the Ferroxcube data
sheet.
SI :
F=
H dl = N I H le
H
(4)
NI
amper-turns/meter (A-T/m)
le
SI :
Where:
H = magnetizing force (ampere-turns/meter)
N = number of turns
le = core magnetic path length (m)
I = peak magnetizing current (amperes)
Topic 4
F=
H dl = 0.4 N I H le
H
0.4 N I
(Oersteds)
le
E dt
N Ae
(5)
10 8
E dt
N
N d N Ae d
E= 8
10
dt
10 8 dt
(7)
Where:
H = magnetizing force (Oersteds)
N = number of turns
le = core magnetic path length (m)
I = peak magnetizing current (amperes)
Texas Instruments
(6)
Where:
= flux density (tesla)
N = number of turns
Ae = effective core area (m2)
E = voltage across coil (volts)
1
E dt
N
d
d
E=N
N Ae
dt
dt
=
E dt 10
=
N Ae
Where:
= flux density (Gauss)
N = number of turns
Ae = effective core area (cm2)
E = voltage across coil (volts)
4-5
SLUP304
VIII. BH Curves
ac =
Vin Ton
10 8 (Gauss)
Ae Np
(8)
Lp Ip
10 8 (Gauss)
Ae Np
(9)
max =
Topic 4
Where:
= flux density (Gauss)
Np = number of primary turns
Ton = on time (sec)
Ae = effective core area (cm2)
Vin = voltage (volts)
Lp = primary inductance (Henrys)
Ip = peak primary current (A)
Texas Instruments
4-6
SLUP304
Ve (mm 3 )
Ve(m ) =
1, 000 3
3
(12)
(13)
Topic 4
ac
2
mt (milli Tesla) =
acpeak
10
(10)
(11)
4-7
SLUP304
Where:
p
7.6
at 100C
f
f
(15)
= 4 10 -7
(14)
(16)
Texas Instruments
4-8
SLUP304
Topic 4
(17)
Use Equation 18 to calculate the AC and DC
wire resistance:
Topic 4
(18)
When designing a magnetic, it is sometimes
desirable to use multiple wires in parallel. You
may need to fill a complete layer on the bobbin for
better coupling, for example. Another reason to
parallel wires is that you can use a diameter less
than two times the skin depth and achieve the
required area.
Equation 19 shows the relationship between
wire area, chosen wire area and the ratio of AC-toDC wire losses. From Equation 19, you can
determine the number of parallel wires.
Number of wires in parallel =
(19)
Equation 20 is used for calculating the total
resistance for a given winding, taking into account
AC and DC losses. You can obtain the length per
turn for a chosen bobbin from manufacturer data.
(20)
4-9
SLUP304
(21)
Where:
Buildup (mm)
Diameter of wire (mm)
m = layer
I = RMS current
= skin depth (cm)
(24)
(25)
Total bobbin turns =
Turns per layer Number of available layers
Texas Instruments
(23)
Turns needed
Total bobbin turns available
4-10
SLUP304
Topic 4
Rdc
Winding data and area product for EFD20/10/7 coil former (SMD) with 10-solder pads
Topic 4
Number of
Sections
1
Winding
Area
(mm2)
27.7
Minimum
Average
Winding Width Length of Turn
(mm)
(mm)
13.5
34.1
Area Product
Ae x Aw
(mm2)
859
Type Number
CPHS-EFD20-1S-10P
4-11
SLUP304
6.
7.
Specification
Topic 4
No
Bobbin-Fit
Calculations
No
Change
Wire Size
or Filar
Yes
Build and Test
Magnetic
4-12
SLUP304
Topic 4
Quasi-Resonant Flyback
10 W
140 kHz
Input
Minimum Input Voltage
Maximum Input Voltage
Primary Peak Current
Primary RMS Current
85 VAC, 76 VDC
265 VAC, 375 VDC
1.155 A
0.425 A
Outputs
Secondary Output Voltage
Secondary Peak Current
Secondary RMS Current
Bias Voltage
Bias Current
5V
13.861 A
5.382 A
16 V
50 mA
190.918 H
3.818 H
12
Texas Instruments
4-13
SLUP304
Topic 4
Texas Instruments
4-14
SLUP304
1/2
= 48 primary turns
Topic 4
Ns =
Np
=4
Turns ratio
7.6
= 0.0203 cm
f
Copper
Diameter
in cm
Copper
Radius
in cm
26
28
30
32
0.04
0.032
0.025
0.02
0.02
0.016
0.0125
0.01
Copper /cm at
Area in 100C
cm2
0.001287
0.00081
0.000509
0.00032
0.001789
0.002845
0.004523
0.007192
Texas Instruments
4-15
SLUP304
Area 26AWG cm 2
=1
Area ring 26AWG 100C cm 2
Area 28AWG cm 2
=1
Area ring 28AWG 100C
Area 30AWG cm 2
=1
Area ring 30AWG 100C
Area 32AWG cm 2
=1
Area ring 32AWG 100C
Rcopper 28AWG 100C = wire 28AWG ohms/cm 100C Rskin 28AWG 100C = 2.845 10 -3ohms/cm
Rcopper 30AWG 100C = wire 30AWG ohms/cm 100C Rskin 30AWG 100C = 4.523 10 -3ohms/cm
Texas Instruments
4-16
SLUP304
Topic 4
34.1 mm
= 3.41 cm
10
Pcopper primary loss 26AWG = Iprimary rms 2 Rcopper primary 26AWG = 0.053 W
Topic 4
J = 400 A/cm 2
Isecondary_rms
= 14 10 -3 cm 2
J
Secondary wire area cm 2
= 16.667
Number of wires secondary 28AWG =
Area 28AWG cm
Rskin 28AWG 100C
Pcopper secondary loss 28AWG = Isecondary rms 2 Rcopper secondary 28AWG = .226 W
Vbias
13
Vout
Texas Instruments
4-17
SLUP304
MBW015
500
-25C
-100C
B
(mT)
3F3
400
300
200
100
0
-25
50
150
H (A/m)
250
Courtesy of Ferroxcube
Topic 4
25
Where:
Pcore = 60 kW/m3
Lp Ipri _ p
10 8 =
Ae Np
10
MBW048
3F3
T=100 C
Pv
(kW/m 3)
10
10
25
kHz
Where:
Ae = .31 cm2
Np = 48
Ipri_p = 1.155 A
Tonmax = 2.9 x 10-6
700
kH
z
400
kH
z
200
kHz
100
kHz
ac =
10
10
10
B (mT)
10
Figure 6
Figure 15
Specific power loss as a function of
Specific power loss as a function of peak
peak flux
density
frequencyasasa parameter.
a parameter
flux densitywith
with frequency
(courtesy of Ferroxcube).
ac
= 740.85 Gauss
2
Buinpolar Gauss
Bunipolar mT =
= 74.085 mT
10
Bunipolar =
Texas Instruments
4-18
SLUP304
Ve per m 3 =
Ve
= 1.46 10 -6 m 3
3
1,000
AWG
Copper Diameter
in cm with
Insulation
0.046
0.037
0.03
0.024
Copper Area
in cm2 with
Insulation
0.001671
0.001083
0.000704
0.000459
Topic 4
Winding data and area product for EFD20/10/7 coil former (SMD) with 10-solder pads
Number of
Sections
1
Winding
Area
(mm2)
27.7
Minimum
Average
Winding Width Length of Turn
(mm)
(mm)
13.5
34.1
Area Product
Ae x Aw
(mm2)
859
Type Number
CPHS-EFD20-1S-10P
Texas Instruments
4-19
SLUP304
Bobbin width cm
2 27
Diameter 26AWG with isolation
Buildup in cm =
Layers =
Winding area cm 2
= .205 cm
Bobbin width cm
Buildup in cm
4
Diameter 26AWG with isolation
Winding factor =
Topic 4
4-20
SLUP304
XVII. References
Topic 4
Texas Instruments
4-21
SLUP304
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SLUP304
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