CH 15 Slides

Chapter 15 Transformer Design
Some more advanced design issues, not considered in previous

chapter:
n1 : n2
Inclusion of core loss

+
+
i
(t)
1
Selection of operating flux

v2(t)
v1(t)
density to optimize total loss
Multiple winding design: as in

the coupled-inductor case,
allocate the available window
area among several windings
R1
R2
+
A transformer design
procedure
ik (t)
vk(t)
How switching frequency

affects transformer size
Fundamentals of Power Electronics
i2(t)
: nk
1
Rk
Chapter 15: Transformer design
Chapter 15 Transformer Design
15.1
Transformer design: Basic constraints
15.2
A step-by-step transformer design procedure
15.3
Examples
15.4
AC inductor design
15.5
Summary
15.1 Transformer Design:

Basic Constraints
Core loss
P fe = K fe(B) A c l m
Typical value of for ferrite materials: 2.6 or 2.7
B is the peak value of the ac component of B(t), i.e., the peak ac flux
density
So increasing B causes core loss to increase rapidly
This is the first constraint
Flux density
Constraint #2
v1(t)
Flux density B(t) is related to the

applied winding voltage according
to Faradays Law. Denote the voltseconds applied to the primary
winding during the positive portion
of v1(t) as 1:
area 1
t1
t2
t2
1 =
v1(t)dt
t1
This causes the flux to change from

its negative peak to its positive peak.
From Faradays law, the peak value
of the ac component of flux density is
B =
1
2n 1A c
To attain a given flux density,

the primary turns should be
chosen according to
n1 =
4
1
2BA c
Copper loss
Constraint #3
Allocate window area between windings in optimum manner, as
described in previous section
Total copper loss is then equal to
Pcu =
with
2 2
1 tot
(MLT)n I
WAK u
I tot =
j=1
nj
n1 I j
Eliminate n1, using result of previous slide:
21 I 2tot
Pcu =
4K u
(MLT )
W A A 2c
1
B
Note that copper loss decreases rapidly as B is increased
Total power loss

4. Ptot = Pcu + Pfe
Power
loss
Co
Ptot = Pfe + Pcu
fe
ss P
Co
ss P c
r lo
ppe
Ptot
re l
o
There is a value of B
that minimizes the total
power loss
Optimum B
21 I 2tot
Pcu =
4K u
(MLT )
W A A 2c
1
B
6
5. Find optimum flux density B

Given that
Ptot = Pfe + Pcu

Then, at the B that minimizes Ptot, we can write
dP fe
dPcu
dPtot
=
+
=0
d(B) d(B) d(B)
Note: optimum does not necessarily occur where Pfe = Pcu. Rather, it
occurs where
dP fe
dPcu
=
d(B)
d(B)
Take derivatives of core and copper loss

dP fe
= K fe (B)
d(B)
Now, substitute into
B =
21 I 2tot
2K u
Aclm
21 I 2tot
Pcu =
4K u
(MLT )
W A A 2c
21 I 2tot
dPcu
=2
d(B)
4K u
dP fe
dPcu
=
d(B)
d(B)
1
+2
(MLT )
1
3
W A A c l m K fe
1
B
(MLT)
3
(B)
W A A 2c
and solve for B:
Optimum B for a
given core and
application
Total loss
Substitute optimum B into expressions for Pcu and Pfe. The total loss is:
Ptot = A c l m K fe
21 I 2tot
2
+2
4K u
(MLT )
W A A 2c
+2
+2
2
+2
Rearrange as follows:
WA Ac
2( 1)/
(MLT )l m2/
+2
Left side: terms depend on core

geometry
2
+2
+2
2/
21 I 2tot K fe
4K u Ptot
+ 2 /
Right side: terms depend on

specifications of the application
The core geometrical constant Kgfe

Define
K gfe =
WA Ac
2( 1)/
(MLT)l m2/
+2
2
+2
+2
Design procedure: select a core that satisfies

2/
K gfe
21 I 2tot K fe
4K u Ptot
+ 2 /
Appendix D lists the values of Kgfe for common ferrite cores

Kgfe is similar to the Kg geometrical constant used in Chapter 14:
Kg is used when Bmax is specified
Kgfe is used when B is to be chosen to minimize total loss
10
15.2 Step-by-step
transformer design procedure
The following quantities are specified, using the units noted:
Wire effective resistivity

(-cm)
Total rms winding current, ref to pri
Itot
(A)
Desired turns ratios
n2/n1, n3/n1, etc.
Applied pri volt-sec
1
(V-sec)
(W)
Allowed total power dissipation
Ptot
Winding fill factor
Ku
Core loss exponent

Core loss coefficient
Kfe
(W/cm3T)
Other quantities and their dimensions:
Core cross-sectional area
Ac
Core window area
WA
Mean length per turn
MLT
Magnetic path length
le
Wire areas
Aw1,
Peak ac flux density
B
11
(cm2)
(cm2)
(cm)
(cm)
(cm2)
(T)
Procedure
1.
Determine core size

2/
K gfe
21 I 2tot K fe
4K u Ptot
+ 2 /
10 8
Select a core from Appendix D that satisfies this inequality.

It may be possible to reduce the core size by choosing a core material
that has lower loss, i.e., lower Kfe.
12
2.
Evaluate peak ac flux density
21 I 2tot (MLT )
1
B = 10
2K u W A A 3c l m K fe
1
+2
At this point, one should check whether the saturation flux density is
exceeded. If the core operates with a flux dc bias Bdc, then B + Bdc
should be less than the saturation flux density Bsat.
If the core will saturate, then there are two choices:
Specify B using the Kg method of Chapter 14, or
Choose a core material having greater core loss, then repeat
steps 1 and 2
13
3. and 4.
Evaluate turns
Primary turns:
n1 =
1
10 4
2BA c
Choose secondary turns according to

desired turns ratios:
n2 = n1
n2
n1
n3 = n1
n3
n1
14
5. and 6.
Choose wire sizes
Fraction of window area

assigned to each winding:
Choose wire sizes according

to:
n 1I 1
1 =
n 1I tot
n 2I 2
2 =
n 1I tot
1K uWA
n1
2K uWA
A w2
n2
A w1
n kI k
k =
n 1I tot
15
Check: computed transformer model

Predicted magnetizing
inductance, referred to primary:
n1 : n2
i1(t)
n 21 A c
LM =
lm
iM (t)
i2(t)
LM
Peak magnetizing current:
1
i M, pk =
2L M
R1
R2
Predicted winding resistances:
ik(t)
n 1(MLT)
A w1
n (MLT)
R2 = 2
A w2
R1 =
: nk
16
Rk
15.4.1
Example 1: Single-output isolated

Cuk converter
Ig
4A
+ vC1(t)
vC2(t) +
25 V
20 A
Vg
v1(t)
v2(t)
V
5V
i1(t)
n:1
i2(t)
100 W
fs = 200 kHz
D = 0.5
n=5
Ku = 0.5
Allow Ptot = 0.25 W
Use a ferrite pot core, with Magnetics Inc. P material. Loss

parameters at 200 kHz are
Kfe = 24.7
= 2.6
17
Waveforms
v1(t)
VC1
Applied primary voltseconds:
Area 1
D'Ts
DTs
i1(t)
1 = DTsVc1 = (0.5) (5 sec ) (25 V)

= 62.5 Vsec
nVC2
Applied primary rms

current:
I/n
I1 =
Ig
i2(t)
+ D' I g
=4A
Applied secondary rms

current:
I 2 = nI 1 = 20 A
Total rms winding

current:
I tot = I 1 + 1n I 2 = 8 A
nIg
D nI
18
Choose core size

(1.72410 6)(62.510 6) 2(8) 2(24.7) 2/2.6
8
K gfe
10
4 (0.5) (0.25) 4.6/2.6
= 0.00295
Pot core data of Appendix D lists 2213 pot core with
Kgfe = 0.0049
Next smaller pot core is not large enough.
19
Evaluate peak ac flux density

1/4.6
(1.72410 6 )(62.510 6 ) 2(8) 2

(4.42)
1
B = 10
3
2 (0.5)
(0.297)(0.635) (3.15) (2.6)(24.7)
8
= 0.0858 Tesla
This is much less than the saturation flux density of approximately

0.35 T. Values of B in the vicinity of 0.1 T are typical for ferrite
designs that operate at frequencies in the vicinity of 100 kHz.
20
Evaluate turns
6
(62.510
)
n 1 = 10 4
2(0.0858)(0.635)
= 5.74 turns
n1
n 2 = n = 1.15 turns
In practice, we might select
n1 = 5
and
n2 = 1
This would lead to a slightly higher flux density and slightly higher
loss.
21
Determine wire sizes

Fraction of window area allocated to each winding:
1 =
4A
8A
2 =
1
5
(Since, in this example, the ratio of

winding rms currents is equal to the
turns ratio, equal areas are
allocated to each winding)
= 0.5
20 A
8A
= 0.5
From wire table,

Appendix D:
Wire areas:
(0.5)(0.5)(0.297)
= 14.810 3 cm 2
(5)
(0.5)(0.5)(0.297)
A w2 =
= 74.210 3 cm 2
(1)
A w1 =
22
AWG #16
AWG #9
Wire sizes: discussion

Primary
5 turns #16 AWG
Secondary
1 turn #9 AWG
Very large conductors!
One turn of #9 AWG is not a practical solution
Some alternatives
Use foil windings
Use Litz wire or parallel strands of wire
23
Effect of switching frequency on transformer size

for this P-material Cuk converter example
4226
0.1
2616
2616
2213
2213
1811
0.08
0.06
1811
0.04
Bmax , Tesla
Pot core size
3622
0.02
0
25 kHz
50 kHz
100 kHz
200 kHz
250 kHz
400 kHz
500 kHz
1000 kHz
Switching frequency
As switching frequency is
increased from 25 kHz to
250 kHz, core size is
dramatically reduced
As switching frequency is
increased from 400 kHz to
1 MHz, core size
increases
24
15.3.2
Example 2
Multiple-Output Full-Bridge Buck Converter
Q1
D1
Q3
T1
D3
n1 :
I5V
: n2
160 V
100 A
D5
+
Vg
i2a(t)
i1(t) v1(t)
5V
Q2
D2
Q4
D6
i2b(t)
: n2
D4
I15V
: n3
i3a(t)
150 kHz
Transformer frequency
75 kHz
Turns ratio
110:5:15
Optimize transformer at
D = 0.75
15 A
D7
Switching frequency
15 V
D8
i2b(t)
: n3
25
Other transformer design details

Use Magnetics, Inc. ferrite P material. Loss parameters at 75 kHz:
Kfe = 7.6 W/Tcm3
= 2.6
Use E-E core shape
Assume fill factor of
Ku = 0.25
(reduced fill factor accounts for added insulation required

in multiple-output off-line application)
Allow transformer total power loss of

Ptot = 4 W
(approximately 0.5% of total output power)
Use copper wire, with

= 1.724106 -cm
26
Applied transformer waveforms

v1(t)
T1
D3
n1 :
: n2
Area 1
= Vg DTs
Vg
i2a(t)
D5
Vg
i1(t) v (t)
1
n
n2
I 5V + 3 I 15V
n1
n1
i1(t)
D4
D6
i2b(t)
0
: n2
: n3
i3a(t)
D7
i2a(t)
n
n2
I 5V + 3 I 15V
n1
n1
I5V
0.5I5V
0
D8
i2b(t)
i3a(t)
I15V
0.5I15V
0
: n3
0
DTs
27
Ts
Ts+DTs 2Ts
Applied primary volt-seconds

v1(t)
Vg
Area 1
= Vg DTs
0
0
Vg
1 = DTsVg = (0.75) (6.67 sec ) (160 V) = 800 Vsec
28
Applied primary rms current

i1(t)
n
n2
I 5V + 3 I 15V
n1
n1
n
n2
I 5V + 3 I 15V
n1
n1
n2
n3
I 1 = n I 5V + n I 15V
1
1
29
D = 5.7 A
Applied rms current, secondary windings

i2a(t)
I5V
0.5I5V
0
i3a(t)
I15V
0.5I15V
0
0
DTs
Ts
Ts+DTs 2Ts
I 2 = 12 I 5V 1 + D = 66.1 A
I 3 = 12 I 15V 1 + D = 9.9 A
30
Itot
RMS currents, summed over all windings and referred to primary
I tot =
all 5
windings
nj
n2
n3
n1 I j = I 1 + 2 n1 I 2 + 2 n1 I 3
= 5.7 A + 5 66.1 A + 15 9.9 A

110
110
= 14.4 A
31
Select core size

(1.72410 6)(80010 6) 2(14.4) 2(7.6) 2/2.6
8
K gfe
10
4 (0.25) (4) 4.6/2.6
= 0.00937
From Appendix D
32
Evaluate ac flux density B
Eq. (15.20):
2 2
8
1I tot (MLT)
1
Bmax = 10
2K u WAA 3c l m K fe
1
+2
Plug in values:
1/4.6
(1.72410 6 )(80010 6 ) 2(14.4) 2

(8.5)
1
B = 10
3
2(0.25)
(1.1)(1.27) (7.7) (2.6)(7.6)
8
= 0.23 Tesla
This is less than the saturation flux density of approximately 0.35 T
33
Evaluate turns
Choose n1 according to Eq. (15.21):
n1 =
1
10 4
2BA c
To obtain desired turns ratio

of
(80010 6)
n 1 = 10
2(0.23)(1.27)
= 13.7 turns
4
110:5:15
we might round the actual
turns to
Choose secondary turns

according to desired turns ratios:
22:1:3
Increased n1 would lead to
5
n2 =
n = 0.62 turns
110 1
Less core loss

More copper loss
15
n = 1.87 turns
n3 =
110 1
Rounding the number of turns
Increased total loss

34
Loss calculation
with rounded turns
With n1 = 22, the flux density will be reduced to
(80010 6 )
B =
10 4 = 0.143 Tesla
2(22)(1.27)
The resulting losses will be
Pfe = (7.6)(0.143) 2.6(1.27)(7.7) = 0.47 W

(8.5)
(1.72410 6)(80010 6) 2(14.4) 2
8
1
Pcu =
10
4 (0.25)
(1.1)(1.27) 2 (0.143) 2
= 5.4 W
Ptot = Pfe + Pcu = 5.9 W
Which exceeds design goal of 4 W by 50%. So use next larger core
size: EE50.
35
Calculations with EE50

Repeat previous calculations for EE50 core size. Results:
B = 0.14 T, n1 = 12, Ptot = 2.3 W
Again round n1 to 22. Then
B = 0.08 T, Pcu = 3.89 W, Pfe = 0.23 W, Ptot = 4.12 W
Which is close enough to 4 W.
36
Wire sizes for EE50 design

Window allocations
Wire gauges
1 =
I1
= 5.7 = 0.396
I tot 14.4
2 =
n 2I 2
= 5 66.1 = 0.209
n 1I tot 110 14.4
1K uWA (0.396)(0.25)(1.78)
=
= 8.010 3 cm 2
(22)
n1
AWG #19
KW
(0.209)(0.25)(1.78)
= 93.010 3 cm 2
A w2 = 2 u A =
(1)
n2
n 3I 3
= 15 9.9 = 0.094
n 1I tot 110 14.4
AWG #8
KW
(0.094)(0.25)(1.78)
= 13.910 3 cm 2
A w3 = 3 u A =
(3)
n3
3 =
A w1 =
AWG #16
Might actually use foil or Litz wire for secondary windings
37
Discussion: Transformer design
Process is iterative because of round-off of physical number of

turns and, to a lesser extent, other quantities
Effect of proximity loss
Not included in design process yet
Requires additional iterations
Can modify procedure as follows:

After a design has been calculated, determine number of layers in
each winding and then compute proximity loss
Alter effective resistivity of wire to compensate: define
eff = Pcu/Pdc where Pcu is the total copper loss (including proximity
effects) and Pdc is the copper loss predicted by the dc resistance.
Apply transformer design procedure using this effective wire

resistivity, and compute proximity loss in the resulting design.
Further iterations may be necessary if the specifications are not
met.
38
15.4 AC Inductor Design

i(t)
Window area WA
Core mean length

per turn (MLT )
v(t)
Core
Core area
Ac
n
turns
Air gap
lg
Wire resistivity
Fill factor Ku
v(t)
Area
t1
t2
i(t)
Design a single-winding inductor, having

an air gap, accounting for core loss
(note that the previous design procedure of
this chapter did not employ an air gap, and
inductance was not a specification)
39
Outline of key equations

Obtain specified inductance:
Total loss is minimized when
0 Acn2
L=
lg
Relationship between
applied volt-seconds and
peak ac flux density:
2 2
B =
I
2K u
(MLT )
1
3
W A A c l m K fe
1
+2
Must select core that satisfies

2/
B =
2nA c
K gfe
2I 2K fe
2K u Ptot
+ 2 /
Copper loss (using dc

resistance):
See Section 15.4.2 for step-by-step

design equations
n 2(MLT ) 2
Pcu =
I
K uW A
40

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Chapter 15 Transformer Design

Some more advanced design issues, not considered in previous

Inclusion of core loss

Selection of operating flux

Multiple winding design: as in

How switching frequency

Fundamentals of Power Electronics

Chapter 15: Transformer design

Chapter 15 Transformer Design

Transformer design: Basic constraints

A step-by-step transformer design procedure

Fundamentals of Power Electronics

Chapter 15: Transformer design

15.1 Transformer Design:

Fundamentals of Power Electronics

Chapter 15: Transformer design

Flux density B(t) is related to the

This causes the flux to change from

Fundamentals of Power Electronics

To attain a given flux density,

Chapter 15: Transformer design

Eliminate n1, using result of previous slide:

Note that copper loss decreases rapidly as B is increased

Fundamentals of Power Electronics

Chapter 15: Transformer design

Total power loss

Ptot = Pfe + Pcu

Chapter 15: Transformer design

5. Find optimum flux density B

Ptot = Pfe + Pcu

Fundamentals of Power Electronics

Chapter 15: Transformer design

Take derivatives of core and copper loss

Now, substitute into

Fundamentals of Power Electronics

and solve for B:

Chapter 15: Transformer design

Left side: terms depend on core

Fundamentals of Power Electronics

Right side: terms depend on

Chapter 15: Transformer design

The core geometrical constant Kgfe

Design procedure: select a core that satisfies

Appendix D lists the values of Kgfe for common ferrite cores

Fundamentals of Power Electronics

Chapter 15: Transformer design

Determine core size

Select a core from Appendix D that satisfies this inequality.

Fundamentals of Power Electronics

Chapter 15: Transformer design

Evaluate peak ac flux density

Fundamentals of Power Electronics

Chapter 15: Transformer design

Choose secondary turns according to

Fundamentals of Power Electronics

Chapter 15: Transformer design

Choose wire sizes

Fraction of window area

Choose wire sizes according

Fundamentals of Power Electronics

Chapter 15: Transformer design

Check: computed transformer model