This document provides design steps for a continuous current buck-boost converter using an LPT E2000Q core. It begins with an overview of the converter topology and operation. It then provides a design example and walks through 30 steps to select the core and design the transformer. The key outputs are selecting an LPT GC60112Q core with 20 turns of AWG 18 wire that meets the current density and loss requirements.
This document provides design steps for a continuous current buck-boost converter using an LPT E2000Q core. It begins with an overview of the converter topology and operation. It then provides a design example and walks through 30 steps to select the core and design the transformer. The key outputs are selecting an LPT GC60112Q core with 20 turns of AWG 18 wire that meets the current density and loss requirements.
This document provides design steps for a continuous current buck-boost converter using an LPT E2000Q core. It begins with an overview of the converter topology and operation. It then provides a design example and walks through 30 steps to select the core and design the transformer. The key outputs are selecting an LPT GC60112Q core with 20 turns of AWG 18 wire that meets the current density and loss requirements.
This document provides design steps for a continuous current buck-boost converter using an LPT E2000Q core. It begins with an overview of the converter topology and operation. It then provides a design example and walks through 30 steps to select the core and design the transformer. The key outputs are selecting an LPT GC60112Q core with 20 turns of AWG 18 wire that meets the current density and loss requirements.
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AN115
Page 1 of 11 AN115 Designing a Continuous Current Buck-Boost Converter Using a LPT E2000Q Core By Colonel Wm. T. McLyman The principle behind flyback converters is based on the storage of energy in the inductor during the charging, or on period, ton, and the discharge of energy to the load during the off period, toff.
Figure 1. Buck-Boost isolated, continuous, current converter.
Energy Transfer In the continuous mode the energy, stored in the primary, is not completely transferred to the secondary, and its circuits, during the off time, before another switching period occurs, as shown in Figure 2. The continuous current B-H is shown in Figure 3. Q1 2Vin 0
Ip Q1
Q1 t
Vs 0
t Is
CR 1
CR1 Io
0 ton
toff T
I = 2Io(min)
Figure 2. Isolated, buck-boost, ideal voltage and current waveforms.
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AN115 Page 2 of 11
B (tesla)
B I H
Bac = B/2
Continuous Current
Figure 3. B-H loop for the continuous current buck-boost converters.
When designing a LPT inductor, and after the core geometry (size) has been selected, then, the correct core permeability can be calculated. Care must be used in selecting the right permeability so the core does not saturate at the maximum amp-turns to which it will be subjected. The dc magnetizing curves for LPT cores are shown in Figure 4. The permeabilities for LPT cores range from 60 to 500 perm. The engineer will select a core with the highest permeability that will not saturate at maximum load current. This core will produce an inductor with the smallest size. 110 100
Percent Permeability
LPT Cores E 2000q
500
80 400 250
60
200 40
125 60
20 0 1
10 100 DC Magnetizing Force (Oersteds)
1000
Figure 4. DC magnetization curves for LPT cores.
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AN115 Page 3 of 11 For a typical design example, assume a buck-boost converter, as shown in Figure 1, with the following specifications: Buck-Boost Isolated Continuous Current Design Specification 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.
Input voltage max ..........................................................................
Input voltage nom .......................................................................... Input voltage min ........................................................................... Output voltage ............................................................................... Output current ............................................................................... Output current ............................................................................... Window utilization ........................................................................ Frequency ..................................................................................... Transformer efficiency .................................................................. Maximum duty ratio....................................................................... Regulation ..................................................................................... Operating flux density ................................................................... Diode voltage ................................................................................ Temperature rise ...........................................................................
Vmax = 32 V Vnom = 28 V Vmin = 24 V Vo = 5 V Io = 10 A Io(min) = 2 A Ku = 0.4 f = 100 kHz = 98 % Dmax = 0.5 = 0.5 % Bm = 0.8 T Vd = 1.0 V Tr = < 30C
Skin Effect The skin effect on an inductor is the same as a transformer. The main difference is that the ac flux is much lower and does not require the use of the same maximum wire size. The ac flux is caused by the delta current, DI, and is normally only a fraction of the dc flux. In this design of a continuous current buck-boost converter, both the dc current density and the high frequency ac current density, will be calculated. In many cases, the ac current that is riding on top of the dc current is small enough that it does not effect the overall current density of the single wire used. There are times when the larger wire is just too difficult to wind. Large wire is not only hard to handle, but it does not give the proper lay. It is easier to wind with bi-filar or quad-filar wire with the equivalent cross-section. Step No. 1. Calculate the total period, T. 1 T= f 1 = 10[ s] 100000 Step No. 2. Calculate the maximum transistor on time, ton. T=
ton = TDmax ton = 10 106 0.5 = 5 [ s] Step No. 3. Calculate the minimum duty ratio, Dmin. Dmin =
Vmin Dmax Vmax
Dmin =
24 0.5 = 0.375 32 www.coremaster.com
AN115 Page 4 of 11
Step No. 4. Calculate the secondary, maximum load power, Po(max).
Po( max ) = I o (Vo + Vd ) Po( max ) = 10 (5 + 1) =60 [W] Step No. 5. Calculate the secondary, minimum load power, Po(min). Po (min) = I o (min) (Vo + Vd ) Po (min) = 2 (5 + 1) =12 [W] Step No. 6. Calculate the maximum, input current, I in(max) . Po( max ) I in ( max ) = Vmin 60 I in ( max ) = = 2.55 [A] 24 0.98 Step No. 7. Calculate the minimum, input power, P in(min) . Po
12 Pin ( min ) = =12.2 [W] 0.98 Step No. 8. Calculate the required, primary inductance, Lp. Pin ( min ) =
Lp
(V =
Dmin ) T 2
in (max)
2 Pin (min)
32 0.3752 10 106 =59 [ H] 2 12.2 Step No. 9. Calculate the primary, delta current, I p. Lp =
I p =
Dmax TVmin Lp
0.5 10 106 24 =2.03 [A] 59 106 Step No. 10. Calculate the primary, delta rms current, I p(rms) . I p =
I p ( rms ) = I p I p ( rms ) = 2.03
ton 3T 5 =0.829 [A] 3 10
Step No. 11. Calculate the primary, peak current, Ipk
Po( max ) I in ( max ) = Vmin I in ( max ) =
60 = 2.55 [A] 24 0.98 www.coremaster.com
AN115 Page 5 of 11
Step No. 12. Calculate the primary, rms current, Irms.
( I ) 2 I rms = I 2pk I pk I + Dmax 3
2.032 I rms = 6.12 2 6.12 2.03 + 0.5 = 3.63 [A] 3
Step No. 13. Calculate the energy-handling capability in Watt-seconds, W-s.
Energy =
LI 2pk
2 59 106 6.12 2 Energy = =0.0011 [W-s] 2 Step No. 14. Calculate the electrical conditions, Ke. Ke = 0.145Po Bm2 x104 Ke = 0.145 60 0.82 104 = 0.000557 Step No. 15. Calculate the core geometry, Kg. Kg =
( Energy )
K e
0.00112 =0.00435 [cm5 ] 0.00057 0.5 Step No. 16. Select, from the data sheet, a LPT core, comparable in core geometry, Kg. Kg =
Manufacturer .................................................................................... CMI Magnetic path length ......................................................................... MPL = 5.11 cm Core weight ...................................................................................... Wtfe = 9.5 g Copper weight .................................................................................. Wtcu = 10.3 g Mean length turn .............................................................................. MLT = 3.4 cm Window Area ................................................................................... Wa = 0.849 cm2 Area Product .................................................................................... Ap = 0.204 cm4 Core geometry ................................................................................... Kg = 0.005938 cm5 Surface area ..................................................................................... At = 25.6 cm2 Core Permeability.............................................................................. = 250 Millihenrys per 1000 turns ................................................................ mH = 151 Step No. 17. Calculate the current density, J, using a window utilization Ku = 0.4. J=
AN115 Page 6 of 11 Step No. 18. Calculate the required permeability, . =
Bm MPL 104 0.4 Wa J Ku
0.8 5.11 104
= 248 use 250 0.4 3.14 0.849 387 0.4 Step No. 19. Calculate the number of turns, N. =
L( new)
N = 1000
L(1000)
0.059 =19.8 use 20 [turns] 151 Step No. 20. Calculate the peak flux density, Bm. N = 1000
Bm =
0.4 ( N ) ( I pk ) ( r ) x104
MPL 1.256 20 6.12 250 104 Bm = = 0.752 [T] 5.11 Step No. 21. Calculate the primary wire area, A pw(B) , using a window utilization, Kpu = 0.2 . Apw( B ) =
Wa K pu Np
0.849 0.2 = 0.00849 [cm 2 ] 20 Step No. 22. Select a wire size with the required area from the wire Table. If the area is not within 10% of the required area, then, go to the next smallest size. AWG = #18 Apw( B ) =
Aw( B ) = 0.00823 [cm2 ]
/ cm = 210 Step No. 23. Calculate the primary, current density, wire area, Jp. Jp =
I prms Apw( B )
3.63 =428 [A/cm2 ] 0.00849 Step No. 24. Calculate the skin depth, . The skin depth will be the radius of the wire. 6.62 = f Jp =
6.62 100 103
=0.0209 [cm]
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AN115 Page 7 of 11 Step No. 25 Calculate the diameter of the primary wire, AWG 18, from Step 22. 4 AW ( B ) D=
4 0.00823 = 0.102 [cm] 3.14 Step No. 26. Subtract two times the skin depth, from the diameter, and calculate the new area. Dn = D 2 D=
Dn = 0.102 2 0.0209 = 0.0602 [cm]
Dn2 4 3.14 0.06022 An = = 0.00285 [cm 2 ] 4 Step No. 27. Take the difference between area, A w(B) , and the new area, An. This will be the area An =
for the I current.
AI = Aw( B ) An AI = 0.00823 0.00241 = 0.00402 [cm2 ] Step No. 28. Calculate the primary delta current I p(rms) , current density, J. J=
I p( rms )
AI 0.829 J= = 206 [A/cm 2 ] 0.00402 I p(rms) current density J = 206 A / cm2 Idc current density J = 428 A / cm2 I p(rms) current density < Idc current density Step No. 29. Calculate the primary, winding resistance, Rp. 6 R p = MLT N p 10 cm R p = 3.4 20 210 106 =0.0143 [ ] Step No. 30. Calculate the primary, copper loss, Pp. Pp = I p2 ( rms ) R p Pp = 3.632 0.0143 = 0.188 [W]
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AN115 Page 8 of 11 Step No. 31. Calculate the secondary turns, Ns. Ns =
Step No. 33. Calculate the secondary, delta current, I . I s = I s =
(Vo + Vd ) T Dmin Ls
( 5 + 1.0) 10 106 0.375
3.78 106 Step No. 34. Calculate the secondary, delta rms current, I I s( rms ) = I p
= 5.95 [A]
p(rms)
T (1 Dmin ) 3T
10 0.625 = 2.72 [A] 3 10 Step No. 35. Calculate the secondary, peak current, I s(pk) . I s( rms ) = 5.95
I s ( pk ) =
Po I + (Vo + Vd ) (1 Dmax ) 2
60 5.95 + = 23 [A] 6.0 (1 0.5) 2 Step No. 36. Calculate the peak flux, density, Bm. 0.4 N p I pk 104 Bm = MPL 1.256 20 6.12 250 104 Bm = =0.752 [T] 5.11 Step No. 37. Calculate the secondary, rms current, I s(rms). I s ( pk ) =
2 I 2 I s ( rms ) = I pk I pk I + 3
(1 Dmin )
5.952 I s ( rms ) = 232 23 5.95 + 0.625=15.8 [A] 3
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AN115 Page 9 of 11
Step No. 38 Calculate the secondary, wire area, A sw(B), using a window utilization, Ksu = 0.2 . Asw( B ) =
Wa K su Ns
Asw( B ) =
0.849 0.2 = 0.034 [cm 2 ] 5
Step No. 39 Select a wire size, with the required area, from the wire Table. If the area is not within 10% of the required area, then, go to the next smallest size. AWG = #12 Asw = 0.0331 [cm2 ] / cm = 52.1 Step No. 40. Calculate the secondary I s(rms) , current density, wire area, Js. Js =
I srms Asw( B )
15.3 =477 [A/cm2 ] 0.0331 Step No. 41. Calculate the diameter of the secondary wire, AWG 12, from Step 39. Js =
D=
4 Aw( B )
4 0.0331 =0.205 [cm] 3.1416 Step No. 42. Subtract two times the skin depth, from the diameter, and calculate the new area. D=
Dn = D 2 Dn = 0.205 2 0.0209 = 0.163 [cm] Dn2 4 3.14 0.1632 An = = 0.209 [cm 2 ] 4 Step No. 43. Take the difference between area, A w(B) , and the new area, An. This will be the area An =
for the I current.
AI = Aw( B ) An AI = 0.034 0.0209 = 0.0131 [cm2 ]
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AN115 Page 10 of 11
Step No. 44. Calculate the secondary delta current I s(rms) , current density, J. J=
I s ( rms) AI
2.72 = 208 [A/cm2 ] 0.0131 I s(rms) current density J = 208 A / cm2 J=
I dc current density J = 477 A / cm2
I s(rms) current density < I dc current density Step No. 45. Calculate the winding resistance, Rs. 6 Rs = MLT N s 10 cm Rs = 3.4 5 52.1 106 =0.000886 [] Step No. 46. Calculate the secondary, copper loss, Ps. Ps = I s2 Rs Ps = 15.82 0.000886 = 0.221 [W] Step No. 47. Calculate the window utilization, Ku. N A + N s Asw Ku = p pw Wa 20 0.00823 + 50.0331 = 0.389 0.849 Step No. 48. Calculate the total copper loss, Pcu. Ku =
Pcu = Pp + Ps Pcu = 0.188 + 0.221 = 0.409 [W] Step No. 49. Calculate the regulation, , for this design. Pcu x100 Po 0.409 = 100 = 0.682 [%] 60 Step No. 50. Calculate the magnetizing force in oersteds, Oe. 0.4 N p I pk H= MPL 0.4 3.14 20 6.12 H= =30.1 [Oe] 5.11 Now that the magnetizing force, H, has been calculated, the next step is to see if this magnetizing force could saturate the core. In Figure 4, there is a curve for 250 perm material, located on the horizontal axis of the 30 Oersteds mark. The next step is to see where the 30 oersteds intersect the 250 perm curve. In this design, the inductor still has over 95% of its designed inductance. =
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AN115 Page 11 of 11 Step No. 51. Calculate the ac flux density in tesla, Bac. I 0.4 N p r 104 2 Bac = MPL 1.256 20 1.01 250 104 0.124 [T] Bac = 5.11 Step No. 52. Calculate the watts per kilogram, WK. WK = 8.64 107 f 1.834 Bac2.112 WK = 8.64 107 100,0001.834 0.1242.112 =15.6 [W/kg] Step No. 53. Calculate the core loss, Pfe . mW Pfe = Wtfe 103
g Pfe = 15.6 9.5 103 =0.148 [W] Step No. 54. Calculate the total loss P, core Pfe and copper Pcu, in Watts. P = Pfe + Pcu P = 0.148 + 0.409 = 0.557 [W] Step No. 55. Calculate the watt density, . P = At 0.557 =0.0217 [W/cm2 ] = 25.6 Step No. 56. Calculate the temperature rise in degrees, C. Tr = 450 0.826 Tr = 450 0.02170.826 =19 [C] BIBLIOGRAPHY 1. Colonel William T. McLyman, Transformer and Inductor Design Handbook, Second Edition, Marcel Dekker Inc., New York, 1988. 2. Colonel William T. McLyman, Magnetic Core Selection for Transformers and Inductors, Second Edition, Marcel Dekker Inc., 1997. 3. Colonel William T. McLyman, Designing Magnetic Components for High Frequency, dc-dc Converters, Kg Magnetics, Inc., 1993. Software: For information regarding the above Books and Companion Software for Windows 95', 98' and NT, contact: Kg Magnetics, Inc. 38 West Sierra Madre Blvd, Suite J Sierra Madre, Ca. 91024 Phone: (626) 836-7233, FAX: (626) 836-7263 Web Page: www.kgmagnetics.com Email: [email protected] www.coremaster.com
