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Micrometals, Inc. - Power Cores =20
=20
=20
Home< Material
Details < Power Conversion - DC =
Applications=20
DC =
Inductor Design=20
Examples
| EXAMPLE =
1 |
EXAMPLE =
2 |
Requirements:
45 =
μH at 7.5=20
amps DC
(< 1% ripple current) |
Requirements:
45 =
μH at 7.5=20
amps DC
60μH max at 0 amps DC
(25% saturation =
max)
(<1 % ripple current) |
| Determine=20
importance of the following design considerations: component =
size,=20
temperature rise and cost. |
Example #1: Design=20
Priorities
cost
temperature rise
component =
size |
Example #2: Design=20
Priorities
component size
temperature rise
cost |
| Select=20
appropriate materials to be considered. |
| -26, -52 and -40 =
Materials
should be considered since the inductor requirements do not =
limit=20
swing and these materials are the most cost effective. =
|
-8, -18, -28 and -33 =
Materials=20
should be considered because of the limited swing=20
requirements. |
| Calculate the=20
required Energy Storage (1/2 LI2) |
| 1/2 LI2 =3D =
(1/2) (45)=20
(7.5)2 =3D 1266 μJ |
1/2 LI2 =3D =
(1/2) (45)=20
(7.5)2 =3D 1266 μJ |
| Select core=20
size and shape |
| -26 Material will be =
used in=20
this example. Refer to the Energy Storage Table in Core=20
Loss Increase Due to Thermal Aging, (Figure 4). The T106 =
size=20
toroid will be selected in order to keep the winding =
=93simple=94 and=20
the temperature rise around 25C=B0. The E137 is an =
attractive choice=20
if bobbin winding is preferred. |
The -8 Material is the =
best=20
choice since component size is the primary concern.
The =
Energy=20
Storage Table Core=20
Loss Increase Due to Thermal Aging, (Figure 1), =
indicates that=20
the T94 size toroid is the smallest core able to meet the =
energy=20
storage requirements at < 40C=B0 temperature rise. We =
must also=20
check the % saturation curves found in theCore=20
Loss Increase Due to Thermal Aging text to verify that =
this core=20
will be operating at less than 25% =
saturation. |
| Determine=20
number of turns |
| The =
curve at the top=20
of page 40 indicates the T106 will require 217 ampere-turns =
to=20
produce 1266 μJ.
Therefore,
NI =3D 162 / 7.5 =3D =
29 turns=20
In the case of the E137 core, the =
curves=20
indicate that 162 ampere-turns will be required to provide =
1266 μJ.=20
Therefore,
NI =3D 162 / 7.5 =3D =
22 turns=20
In the case of the T106 toroidal =
core, the=20
=93simple=94 winding limits are close estimates of typical =
single layer=20
windings, refer to the Single=20
Layer Winding Table. This table shows that #7 wire will =
fit in a=20
single layer and result in a 25C=B0 temperature rise from =
the wire. In=20
the case of the E137, referring to the "=
Full=20
Winding" Table indicates that up to #13 wire can be=20
used. |
The curves in theCore=20
Loss Increase Due to Thermal Aging text indicate that =
the T94=20
will be operating at 84.5% of initial permeability (15.5%=20
saturation) to produce 1266 μJ. Use the following =
formula to=20
calculate turns:
Since a =93full=94 winding was =
required to keep=20
the temperature rise of the T94 below 40C=B0, refer to the =
"=
Full=20
Winding" Table. This table indicates that #16 wire =
should be=20
used. This table also contains the information necessary to=20
calculate the DC resistance of a winding. =
|
| Determine wire=20
size |
Solution:
T106-26 =
with 29=20
turns #17
or E137-26 with 22 turns =
#14 |
Solution:
Part =
number=20
T94-8/90
with 46 turns=20
#16 | |
About Us | =
What We Do |=20
Contact Us =
| Samples | =
Catalog |=20
Thermal Aging | Parts | =
Materials |=20
Software | =
Home
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