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Property of Zettler M
agnetics
Zettler Magnetics We know better magnetics
Philip Fung
Standard Transformer Applications
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Property of Zettler M
agnetics
Zettler Magnetics We know better magnetics
General Transformer Glossary• Input Voltage/Current • Output Voltage/Current• Frequency• Topology/Duty Cycle• OCL/Leakage Inductance.• Temperature rise• Ambient Temperature. Ta70B
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Property of Zettler M
agnetics
Zettler Magnetics We know better magnetics
Safety Related Info.
• Output Voltage LimitEN60950… SELV for 42.4Vpk or 60VDC UL5085… Class II 30Vmax
Class III 30-100V or 150V EN61558-2-6… 50VRMS/120V ripple free DC
• Transformer ClassClass I/II/III in EN60950/EN61558 ProtectionClass I/II/III in UL5085 Voltage
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Property of Zettler M
agnetics
Zettler Magnetics We know better magnetics
Safety related info• Insulation Grade
Class A 105C 100C maxClass E 120C 115C maxClass B 130C 120C maxClass F 155C 140C maxClass H 180C 165C max
TEX-E or Twisted WireMW82 wire and etc….
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Property of Zettler M
agnetics
Zettler Magnetics We know better magnetics
Creepage and Clearance
6.4mm creepage
3.2mm margin
Secondary
Primaryand clearance
& clearanceOnly 3.2 mm creepage
leadout
8.2mm creepage & clearance
leadout w/ sleeve
5.0 mm3.2 mm
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Property of Zettler M
agnetics
Zettler Magnetics We know better magnetics
Laminated Transformer Types
• Print PCB Transformer• UI Core low profile pin type transformer• Current Sensing Transformer• Lead type transformer• Power everywhere• New edge why still use the laminated
transformer?
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Property of Zettler M
agnetics
Zettler Magnetics We know better magnetics
Laminated transformer materials • Lamination material
Lamination: Z11, H12, H14, H18, H23, H50
• Standard SizesEI28/30/35/41/48/57/66
• Insulation materialsBobbin (PET, NYLON), TAPE (Polyester), Varnish (C1105, AC43)
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Property of Zettler M
agnetics
Zettler Magnetics We know better magnetics
Standard Ferrite Magnetics SMPS Application
PFC STAG
E
PFC Choke
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Property of Zettler M
agnetics
Zettler Magnetics We know better magnetics
Standard Ferrite Magnetics Ballast Application
Differential Mode ChokeOr Common Mode Choke
PFC Choke
Driver Transformer
Main Output Transformer
Sensing Transformer
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Property of Zettler M
agnetics
Zettler Magnetics We know better magnetics
Choke Types by Application• Common Mode Choke• Differential Mode Choke• Energy Stock Choke (PFC, BUCK)
Choke Types by Material
• Ferrite Core• Powdered Core (iron, MPP, Sendust)• Laminated Core (EI, taped, Amorphous)
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Property of Zettler M
agnetics
Zettler Magnetics We know better magnetics
Ferrite XFMR Types by Application• Flyback XFMR (with Gap)• Forward XFMR • PushPull• Full bridge
Ferrite XFMR Types by Shapes• EE 13, EE 16… … • EFD20, • ER28, ETD34…• Planar E40
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Property of Zettler M
agnetics
Zettler Magnetics We know better magnetics
Ferrite XFMR Material• TDK PC-40• Nicera NC-2H• China Material TDG, DMEGC ……
Ferrite XFMR Bobbins• EE 13, EE 16… … • EFD20, • ER28, ETD34…• Phenolic PM9820 T375J
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Property of Zettler M
agnetics
Zettler Magnetics We know better magnetics
NO., Supplier Quality(50)Cost(15)
Delivery time(15)
Service(20) Total Grade
1 TDK 48 11 10 17 86 A
2 TDG 47 12 12 18 89 A
3 ACME 47 14 12 19 92 A
4 DMEGC 47 14 14 18 93 A
6 NEC 45 11 12 16 84 B
5 MAGSOURCE 43 14 12 15 84 B
7 GUANDA 40 15 10 14 79 C
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Property of Zettler M
agnetics
Zettler Magnetics We know better magneticsItem SymbolConditions Unit NiceraNC-2H
TDKPC47
TDKPC40
TDGTP4
TDGTP4A
DMEGCDRM40
DMEGCDRM44
ACMEP4
ACMEP41
Initial permeability
μiF:10KHzB
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Property of Zettler M
agnetics
Zettler Magnetics We know better magnetics
Key Parameters Affect to your power supply• Leakage Inductance
L1
1u
VDrain
TX2
R5
1K
C3330p
R91.8
Q1
IRFR420
X
R81k
R1
100
C6330p
2uH 250V peak spike
20uH 350V Peak Spike
22
21
21 CVLI =
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Property of Zettler M
agnetics
Zettler Magnetics We know better magnetics
Leakage Inductance
∫a
dxxLo0
2∝cLo ++
3a2a1 ∝
)3
a2a1(*XK cLo ++=
How about Multi-section?
)3
a2a1( ∝ cLo ++
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Property of Zettler M
agnetics
Zettler Magnetics We know better magnetics
Leakage InductanceThe power to transform
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Property of Zettler M
agnetics
Zettler Magnetics We know better magnetics
Key Parameters Affect to your power supply
fDdep 76=
???2DCRXIPcopper =
???* 2IDCRPcopper =
I(t)
H(t)
I(t)
J(t) J(t)
0
Eddy currents
raa
B sin( ωt)
+ -- + - +
+ -
B sin( ωt)
Wire Diameter Skin Effect Copper loss
NO, the SKIN effect caused a Rac
KRdcRac *=
• Mnimize eddy currents using Leitz wire bundle. Each conductor in bundle has a diameter less than a skin depth.
• Twisting of paralleled wires causes effects of
intercepted flux to be canceled out between adjacent twists of the conductors. Hence little if any eddy currents.
IS:2I*K*RdcsPCopperLos =
Not Really, the proximity effect.
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•Mnimize eddy currents using Leitz wire bundle. Each conductor in bundle has a diameter less than a skin depth.
•Twisting of paralleled wires causes effects of intercepted flux to be canceled out between adjacent twists of the conductors. Hence little if any eddy currents.
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Property of Zettler M
agnetics
Zettler Magnetics We know better magnetics
Proximity Effect
Rac=RdcXFr Famous Dowell Curve
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Property of Zettler M
agnetics
Zettler Magnetics We know better magnetics
Gap Fringing Effect
• Fringing cause significant eddy loss
• Avoid the fringing lossby design
• Fringing increases theOCL
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Property of Zettler M
agnetics
Zettler Magnetics We know better magnetics
Core Losses
• Core Loss mW/cm^3 or mW/gram• Different loss from different material• Select right materials
Not over design• B vs Core loss
No stress design
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Property of Zettler M
agnetics
Zettler Magnetics We know better magnetics
Gap, ue, Bdc
• Bsat inherent characteristics
• Bdc decided by peak current
• OCL decided by turns and gapping size
• Basic formula:1 .10 3 0.01 0.1 1
0
500
1000
1500
2000
2500
3000
3500
4000
4500
µi
µrev ∆B BM,( )
µrev1 ∆B BM,( )
BM
lelgui1
uiue+
=le
NIπ4.0H =
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Property of Zettler M
agnetics
Zettler Magnetics We know better magnetics
Powder Core Characteristics• Distribute gap• Soft Saturation• Different powder size
different core loss• Thermal Aging issue• Choose right core
materials
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Property of Zettler M
agnetics
Zettler Magnetics We know better magnetics
Common Mode Choke• Impedance
1 .103 1 .104 1 .105 1 .106 1 .107 1 .108 1 .109 1 .10100.1
1
10
100
1 .103
Radians/sec
Ohm
s
943.503
0.895
Z.in 1jωi⋅( )
4.472 109×5.135 103× ωi
L1
1m
• EMI Filtering Network• Mostly are low pass LC
filtering circuit.
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Property of Zettler M
agnetics
Zettler Magnetics We know better magnetics
EMI Filtering Net Work
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Property of Zettler M
agnetics
Zettler Magnetics We know better magnetics
Magnetics Thermal Engineering
• Temperature Rise. Ploss includes copper loss and core loss
833.0)(
=
AsurfmwPlossdT
• Forced Ventilation Effect 0 15 30 45 60 75 90 105 120 135 1500.2
0.29
0.38
0.47
0.56
0.64
0.73
0.82
0.91
1Tempearure rise Vs Air flow
Cubic Feets Minutes
% T
empe
ratu
re
f x( )
x
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Property of Zettler M
agnetics
Zettler Magnetics We know better magnetics
Magnetics IS one of the most important portion in the power supply design
• Thank You for AttendingPhilipFungZETTLER MAGNETICS
[Reference]Leakage Inductance by N.H. Crowhurst 1949Soft Ferrites, Properties and Applications, 2nd Edition 1988 by Snelling E.C.Switching Mode Power supply Handbook by Keith. H. BillingsMicrometals Catalogue Edition 2000Magnetics Calalogue
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Philip Fung� General Transformer Glossary Safety Related Info. Safety related info Creepage and ClearanceLaminated Transformer Types Laminated transformer materials Standard Ferrite Magnetics SMPS Application Standard Ferrite Magnetics Ballast Application Choke Types by ApplicationFerrite XFMR Types by ApplicationFerrite XFMR MaterialSlide Number 13Slide Number 14 Key Parameters Affect to your power supplyLeakage InductanceLeakage InductanceKey Parameters Affect to your power supplyProximity Effect Gap Fringing EffectCore LossesGap, ue, BdcPowder Core CharacteristicsCommon Mode Choke EMI Filtering Net WorkMagnetics Thermal EngineeringMagnetics IS one of the most important portion in the power supply design
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