Air Core Inductor Design Program

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Your support and service is exceptionalThis article explores the differences between capacitor and inductor types utilized in the crossover designs and how they may affect measurable and sonic performance. The inductor calculator presented on this page is unique in that it employs the n0 sheath helix waveguide mode to determine the inductance of a coil, irrespective of. Wireless Energy Transmission Coils as Key Components. Presented By Wrth Elektronik. Why is wireless energy transmission gaining importance now even though the. I have used Coilcraft for many years, and always specify your products for peace of mind. Extremely reliable service, great products, I will always buy Coilcraft. Ive been impressed for many years with how you understand the needs of engineers to get samples and parts quickly and easily. This makes it very convenient to design in Coilcraft. Also that you keep improving and innovating inductor design. Air Core Inductor Design Program' title='Air Core Inductor Design Program' />Coilcraft is wonderful We appreciate your investment in high performance and repeatable inductor design and fabrication. Your willingness to sample parts makes you much more likely to be designed in to our products than your competitors. HTB1iH5iLpXXXXcaXpXXq6xXFXXXU/Toroidal-RF-Inductor-with-Air-Core-RF.jpg' alt='Air Core Inductor Design Program' title='Air Core Inductor Design Program' />Im a low volume user but it is nice to be treated like a first class customer. Coilcraft is our 1, also because of the excellent service Coilcraft inductors are always high quality. Also I really like the models you provide, they are very accurate and useful during simulations. Coilcraft inductors are in my view the best of the best they are my goto on new designs. I am a contract design house and using the best parts on my work and reflects well. 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Before discussing the calculation of magnetic components for switching power supplies, let me just quickly go over the basic concepts and definitions. Transformer is a passive device which transfers alternating AC electric energy from one circuit into another through electromagnetic induction. It consists of a ferromagnetic core and two or more coils windings. A changing current in the primary winding creates an alternating magnetic field in the core. The core multiplies this field and couples most of the flux through the secondary windings. This in turn induces alternating voltage electromotive force, or emf in each of the secondary coil according to Faradays law. Power transformer in SMPS is used to change amplitude of high frequency pulses by the turns ratio and to provide isolation between circuits. Note that a transformer cant transfer a DC component of a pulse in a steady state mode net volt seconds across any winding should be zero, otherwise the core will soon saturate. DC output voltage can be obtained only by using rectifiers. Nevertheless, an average voltage across a real coils terminals can be non zero due to non zero wire resistance. This DC offset can be used for lossless sensing of an average current across an inductor or a transformer winding with unidirectional current if you add an RC network parallel to the coil, the voltage across the capacitor will be proportional to the coils average current. For better thermal stability the wire can be made of low TCR material, such as a copper alloy. MAGNETICS DESIGNING normally involves trade offs between size, cost and power losses. The main constraint in all cases except for saturable inductors is that peak magnetic flux density BMAX should not approach the core materials saturation flux value BSAT. Note that in higher frequencies, core loss rather than saturation can become the main limiting factor for BMAX. The flux change is a function of the applied volt seconds and the core geometry. Excessive volt seconds applied to a coil cause core saturation. When it happens, the windings are effectively shorted out. The table below provides the formulas for BMAX in a steady state operation as function of NAc product, applied voltage and frequency for common voltage waveforms. Contrary to popular misconception, BMAX does not depend on the magnetic material properties or air gaps. It does not depend on the transferred power neither. Thats why in theory the core size does not depend on the wattage. However, for efficiency and thermal reasons, we have to limit ohmic losses in the wires. Thats why magnetics size increases with power. Most textbooks provide formulas for estimation of the core size based on the product of magnetic cross section area by the window area available for the winding. Unfortunately, this method is not very helpful because these formulas are based on pretty much arbitrary selection of current density and on the assumption of a certain window utilization fill factor. In reality, depending on the insulation grade and application requirements, current density in the copper can be selected anywhere between 1. Asq. cm. The fill factor likewise can be anywhere between 0. As the result, if you dont have much experience in practical transformer design, you will need to go through several iterations. Here is a quick simplified transformer design procedure. Select the ferrite material based on your operating frequency Find saturation flux BSAT at maximum operating temperature from the datasheet and pick some derating, such as 7. This will be you target maximum flux BMAX Determine minimum required NAc product for the targeted BMAX for the core excitation waveformsee the table to the left Choose a core size based on similar designs and find its effective cross sectional area Ac from the datasheet Find minimum required primary turns N as NAc product divided by Ac Calculate secondary turns for your output voltage based on a DC transfer function of the selected SMPS topology Choose wire size based on your primary and secondary currents, operating frequency, and the available window. When you get an actual prototype you can measure the hot spot temperature by placing a thermocouple under the coil and then adjust the design if necessary. S. A. Mulder proposed an empirical formula for thermal resistance of a wire wound transformer measured at the hot spot Rth5. Ve 0. 5. 4o. Cwatt, where Ve core volume in cubic centimeters 1. Kaspersky Internet Security 2011 Crack - XTREME'>Kaspersky Internet Security 2011 Crack - XTREME. Phillips App Note. From this, a rule of thumb hot spot temperature rise in Celsius vs. Pwatt is Trise5. VeP. Note that the above thermal relationship as well as most textbook procedures related to the magnetics thermal management are applicable to natural convection cooling. For applications with forced airflow or conduction cooling these procedures results in an over designed part because of an overstated temperature rise. In general, ideal SMPS transformers need to transfer all energy instantaneously from one winding to another while storing no or little energy in the process. Some topologies do need certain amount of energy stored in magnetizing inductance for a proper operation. Conversely, a power inductor is used in SMPS as an energy storage device. It accumulates energy in the magnetic field as current flows through it, and then transfers it into another circuit during the alternate part of the switching cycle. In power supplies, the inductors are also used for filtering out high frequency currents in which case they are often called chokes. In power inductors the current rather voltage is controlled. For such current driven coils BLIpk1. NAc. where L inductance in henry, Ipk peak current in amps, B flux in gauss. All units and formulas in this page are given in CGS see CGS to SI unit converter. Once you set BMAX and choose a core size, you can find from the above equation the number of turns for the desired inductance L. NLIpk1. 08BMAXAc. Note that L is not constant. If the current keeps increasing, at some point BMAX will be approaching BSAT and L will start dropping. To prevent the magnetic material saturation at a required current, an air gap can be introduced. The length of a net discrete gap lg0. NIpkBMAX. In practice, the gap may need to be selected slightly larger than the calculated value due to flux fringing. Combining the above equations for N and lg yields lg0. LIpk. 2BMAXAc. The gap is used not only in inductors. It is also often introduced in transformers to increase working flux swing in single ended topologies, to store more energy in magnetizing inductance, and to stabilize the inductance value. For powder metal materials with a distributed gap and soft saturation curve, the calculation process may take several iterations. In short, you can first pick a powder core based on desired LIpk. Then determine the turns, where AL specific inductance in m. H1. 00. 0 turns which is n. Hturn from the data sheet. Then find peak bias H0. NIpkle Oersted, determine the roll off in percentage of initial permeability, and correct the turns for the desired L. Below you will find more magnetics theory, transformer and inductor design information, tutorials, tools and free downloads.