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If interleaving factor (Fh) is OK, go build it. Otherwise, select new interleaves and go back to fitting wire. Obtain materials Wind the coils s Stack the laminations Test the performance If result is OK, you've done. Otherwise, go back and select a new (probably bigger) core size and loop back through the process.
Specifications:
Output voltage, Vo Output current, I o Operating frequency, f Efficiency, Flux Density, B = = = = = 5V 0.75 A 100 K 98% 0.15 T
Output Power P :
o
Po =V I o [W ]
V =Vo +Vd
V = 5 +1 = 6
Po = 6 0.75
P o = 4.5
[W ]
Apparent Power P :
t
27
2 Pt = Po + 2 [W ] 2 Pt = 4.5 0.98 + 2
Pt 4.6
[W ]
( x)
Area Product A :
p
Pt 104 Ap = K B f K K m u j f
[cm ]
4
( 0.12 )
[cm ]
4
For the area product of 1.89 cm 4 , core chosen is 55071 and the appropriate data for this core is Area product A p Inner dia i.d Outer dia o.d Core area Ac Surface area At = = = = = 1.863 cm 4 1.879
cm cm
0.672 cm 2
cm 2
cm cm
Np =
Np =
V p 10 4 K f Bm f Ac
15 10 4 4 0.15 100 0.672
N p 4 [turns]
Ns =
Vs Np Vp
28
Ns =
5 4 15
N s = 1.3 2 [turns]
Primary Current I :
p
Ip =
Ip =
Po V p
4.5 15 0.98
I p = 0.306
[ A]
Current Density J :
J = K j A(py )
J = 403 1.863( 0.12 )
J = 374.0
[ A / cm ]
2
w( B )
:
Aw( B ) =
Aw ( B ) =
I p 0.707 J
0.3 0.707 374
Aw( B ) = 56.7 10 3 cm 2
1A
100 KHz
0.15T
29
Energy K :
2 L Io K= 2
K =
87.5 10 6 2 2 2
K =175
[W
S]
Area product A :
p
2 k 10 4 Ap = B K K u j m
( x)
Ap = 0.110 cm 4
(1.14 )
For the area product of 0.11 cm 4 , core chosen is 55121 and the appropriate data for this core is Area product A p Inner dia i.d Outer dia o.d Core area Ac Surface area At = = = = = 0.123 cm 4 0.902
cm cm
2.247
Magnetic path length MPL = Mean length per turn MLT = Inductance for 1000 turns =
cm cm
35. 10 3 H
Number of turns N :
L N = 1000 L 1000
30
420 10 3 N = 1000 35
N = 12 [turns]
Current Density J :
J = K j A(py )
J = 403 0.123( 0.12 )
J = 518.22 A / cm 2
w( B )
:
Aw( B ) =
Aw ( B ) =
Ip J
[cm ]
2
1 518.22
Aw ( B ) 2 10 3 cm 2
31