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Power Transformers
Contents
Introduction
Design procedure
Design examples
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8
10
Formulas
Layer design
13
14
1
Ferroxcube
Introduction
Planar transformers can be constructed as stand alone
components, with a stacked layer design or a small
multilayer PCB, or integrated into a multilayer board of the
power supply.
layer 1
layer 2
layer 3
multilayer PCB
layer 4
Planar principles
3
Ferroxcube
Design procedure
1. Calculation of maximum flux density
Power losses in our ferrites have been measured as a
function of frequency (f in Hz), peak flux density (B in
T) and temperature (T in C). Core loss density can be
approximated (2) by the following formula :
Ptrafo =
[1]
[3]
[mW/cm3]
In this formula Cm, x ,y, ct0, ct1 and ct2 are parameters
which have been found by curve fitting of the measured
In this formula Rth represents the thermal resistance of the power loss data. These parameters are specific for a ferrite
transformer. Ptrafo can in fact be interpreted as the cooling
material. They are dimensioned in such a way that at
capability of the transformer.
100 C the value of CT is equal to 1.
Previous work (1), showed that it is possible to establish
In table 1 fit parameters are listed for several Ferroxcube
an empirical formula which relates the value of thermal
power ferrites. Maximum allowed Pcore is calculated with
resistance of a transformer directly to the value of the
equation [2]. This value is inserted in equation [3].
effective magnetic volume Ve of the ferrite core used.
Maximum allowed flux density Bpeak can now be calculated
This empirical formula is valid for wire wound transformers by rewriting equation [3]:
with core shapes like RM and ETD. A similar relation has
1/y
now been found for planar E transformers.
Pcore
[4]
[T]
Bpeak =
This relation can be used to estimate the temperature rise
Cm . CT . f x
of the transformer as a function of flux density in the
core. Because of the limited available winding space it is
recommended to use the maximum allowed flux densities
in planar magnetics.
With the assumption that half of the total transformer
loss is core loss, it is possible to express the
B
maximum core loss density Pcore as a function of the
allowed temperature rise T of the transformer as:
Pcore =
R th
12 . T
[mW/cm3]
2 .Bpeak
[2]
Ve ( cm3 )
Bpeak in the formulas is half the peak to peak flux excursion
in the core.
ferrite
3C30
3C90
3C94
3F3
3F4
f (kHz)
Cm
20-100
100-200
20-200
20-200
200-400
100-300
300-500
500-1000
500-1000
1000-3000
7.13.10-3
7.13.10-3
3.2.10-3
2.37.10-3
2.10-9
0.25.10-3
2.10-5
3.6.10-9
12.10-4
1.1.10-11
1.42
1.42
1.46
1.46
2.6
1.63
1.8
2.4
1.75
2.8
ct2
ct1
3.02
3.02
2.75
2.75
2.75
2.45
2.5
2.25
2.9
2.4
3.65.10-4
6.65.10-2
4.10-4
1.65.10-4
1.65.10-4
1.65.10-4
0.79.10-4
0.77.10-4
0.67.10-4
0.95.10-4
0.34.10-4
ct0
.10-2
6.8
3.1.10-2
3.1.10-2
3.1.10-2
1.05.10-2
1.05.10-2
0.81.10-2
1.1.10-2
0.01.10-2
4
3.8
2.45
2.45
2.45
1.26
1.28
1.14
1.15
0.67
Note:
The maximum allowed value for B can also be found in another way.
Formula [3] together with the fit parameters can be inserted into a
computer program which makes it possible to calculate the power losses
for arbitrary wave forms (3). Advantage is that the real wave shape of B
can be simulated to calculate the losses and that it is possible to select the
optimum ferrite for the concerned application.
[ bw - (N1 + 1) . s ]
wt =
[5]
N1
[6]
bw
5
Ferroxcube
Note:
For groups of similar parallel inductors, if closely spaced, the temperature
rise may be found by using an equivalent cross section and equivalent
current. The equivalent cross section is the sum of the cross sections
of the parallel conductors and the equivalent current is the sum of the
currents in the inductor.
Empirical tool
Temperature measurements on several designs of multilayer
PCBs with AC currents supplied to the windings, show
with reasonable accuracy that up to 1MHz each increase
of 100 kHz in frequency gives 2 C extra in temperature
rise of the PCB compared to the values determined for DC
currents.
6
Ferroxcube
100
50
Ieff
(A)
T = 50 oC
T = 40 oC
T = 30 oC
T = 20 oC
20
T = 10 oC
10
5
Conductor
width
(mm)
2
20
10
Cu
35
Cu
0.5
0.2
70
0.1
0.5
0.2
0.1
10-2
10-1
2
5
1
Cross section (mm2)
Fig.2 Relation between current, dimensions of tracks in PCBs and temperature rise.
7
Ferroxcube
Uimin
Uo
UpIC
prim
sec
f
Pmax
Tamb
T
= 70 V
= 8.2 V
= 8V
0.48/0.5
0.48/0.5
120kHz
8W
60oC
35oC
Ae (mm2)
14.5
14.5
39.5
39.5
78.5
78.5
Ve (mm3)
240
300
800
960
2040
2550
N1
63
63
23
23
12
12
N2
7.4
7.4
2.7
2.7
1.4
1.4
NIC
7.2
7.2
2.6
2.6
1.4
1.4
G(m)
113
113
41
41
22
22
8
Ferroxcube
Layers
Turns
solder mask
primary
insulation
primary
insulation
primary IC
insulation
secondary
insulation
primary
insulation
primary
solder mask
TOTAL
6
6
3
3
6
6
35 m
70 m
50 m
35 m
200 m
35 m
200 m
35 m
400 m
35 m
400 m
35 m
200 m
35 m
50 m
50 m
70 m
200 m
70 m
200 m
70 m
400 m
70 m
400 m
70 m
200 m
70 m
50 m
1710 m
1920 m
9
Ferroxcube
output power:
duty cycle:
switching frequency
ambient temperature
allowed temperature rise
48 V
48 V
24 V
24 V
Pmax
f
Tamb
T
5V
3.3 V
5V
3.3 V
18 W
0.46
500kHz
= 40oC
= 50oC
Core
Vin
Vout
N1
N2
Lprim
(H)
Io(RMS)
(mA)
Imag
(mA)
Ip(RMS)
(mA)
E-PLT14
48 V
48 V
24 V
24 V
5V
3.3 V
5V
3.3 V
14
14
7
7
3.2
2.1
3.2
2.1
690
690
172
172
2441
3699
2441
3699
60
60
121
121
543
548
1087
1097
E-E14
48 V
48 V
24 V
24 V
5V
3.3 V
5V
3.3 V
14
14
7
7
3.2
2.1
3.2
2.1
855
855
172
172
2441
3699
2441
3699
48
48
97
97
539
544
1079
1089
Layers
Turns
solder mask
tracks layer
insulation
primary demag.
insulation
primary
insulation
secondary
insulation
secondary
insulation
secondary
insulation
secondary
insulation
primary
insulation
primary demag.
insulation
tracks layer
solder mask
TOTAL
11
Ferroxcube
7
7
3
2
2
3
7
7
70 m
50 m
70 m
200 m
70 m
200 m
70 m
200 m
70 m
200 m
70 m
200 m
70 m
200 m
70 m
200 m
70 m
200 m
70 m
200 m
70 m
50 m
2600 m
References
1. Mulder S.A., 1990
Application note on the design of low profile high
frequency transformers, Ferroxcube Components.
2. Mulder S.A.,1994
Loss formulas for power ferrites and their use in
transformer design,Philips Components.
3. Durbaum Th, Albach M, 1995
Core losses in transformers with an arbitrary shape of the
magnetizing current.1995 EPE Sevilla.
4. Brockmeyer A., 1995
Experimental Evaluation of the influence of DC
premagnetization on the properties of power electronic
ferrites, Aachen University of Technology
5. Ferroxcube Components technical note, 1996
25 Watt DC/DC converter using integrated Planar
Magnetics.(9398 236 26011)
12
Ferroxcube
=
primary self inductance
prim =
effect. path length
sec
=
=
airgap length
a
primary winding turns
e
=
secondary winding turns
0
=
=
=
=
=
=
=
=
=
=
=
=
N1 =
N2 =
NIC =
Uimin . prim
G=
N1 =
2 . f . Bpeak . Ae
N1 . Uo . sec
N2 =
Uimin . prim
UIC . N1
Uimin
Pmax
.
Uo
N1 . Uo
Uimin .
0 . a . N12 . Ae
le
G = not applicable
4
3 . sec
Io(RMS) =
Imag =
2 . f . Bpeak . Ae
Lprim =
0 . N12 . Ae
Lprim
Io(RMS) =
Uimin .
( Uimin . prim ) 2
2 . Pmax . f
Lprim =
Uimin . prim .
f . Lprim
prim
3
Ip(RMS) =
13
Ferroxcube
Pmax
.
Uo
Uimin .
f . Lprim
Io(RMS)
+
r
Imag
.
2
+0.05
10.7 -0.1
hole pattern
layer 1 (top)
layer 6
layer 2
layer 7
layer 8
layer 3
layer 4
layer 9
layer 5
layer 10 (bottom)
14
Ferroxcube
15
Ferroxcube