A Spreadsheet-Based Procedure for

Designing Naturally Cooled Magnetic

Components

William P. Robbins
Dept. of Electrical and Computer Engineering
University of Minnesota

May, 2002
 Magnetic Component Design Problem
• Challenge - conversion of component operating specs
in converter circuit into magnetic component design
parameters.
• Goal - simple, easy-to-use procedure that produces
component design specs that result in an acceptable
design having a minimum size, weight, and cost.
• Inductor electrical (e.g.converter circuit)
specifications.
• Inductance value L
• Inductor currents rated peak current I, rated rms
current Irms , and rated dc current (if any) Idc
• Operating frequency f.
• Allowable power dissipation in inductor or
equivalently maximum surface temperature of the
inductor Ts and maximum ambient temperature Ta.
• Transformer electrical (converter circuit)
specifications.
• Rated rms primary voltage Vpri
• Rated rms primary current Ipri
• Turns ratio Npri/Nsec
• Operating frequency f
• Allowable power dissipation in transformer or
equivalently maximum temperatures Ts and Ta
• Design procedure outputs.
• Core geometry and material.
• Core size (Acore , Aw)
• Number of turns in windings.
• Conductor type and area Acu.
• Air gap size (if needed).
• Ability to compare the performance of different
cores and core materials for the same component.
• Impediments to a simple design procedure.
1. Dependence of Jrms and B on core size because of
losses and magnetic saturation.
2. How to chose a core from a wide range of
materials and geometries.
3. How to design low loss windings at high
operating frequencies.
4. Long tedious calculations required to compare
performance of different cores and materials for
the same component
• Detailed consideration of core losses, winding
losses, high frequency effects (skin and proximity
effects), heat transfer mechanisms required for good
design procedures.
 Manual Transformer Design : Area-Product Method
Start
• Assemble design inputs and compute required V-I rating
Assemble design inputs S = 2 Vpri Ipri

• Choose core geometry, core material, and winding conductor

Compute 2 V pri
I
pri geometry.

Determine core size using • Use 2 Vpri Ipri = 4.4 f kcu Jrms Bac Aw Acore to find the required
assumed values of J and B area product Aw Acore and thus the core size.
• Assume Jrms= 2-4 A/mm2 and Bac = 50-100 mT.
Design winding ( A , Npri ,
cu,pri
A cu,sec , N sec )
• Complete design of transformer as indicated.

Set S max
to desired S
Select • Check power dissipation and surface temperature using
larger assumed values of Jrmsand Bac. If dissipation or
core size temperature are excessive, select a larger core size and repeat
design steps until dissipation/temperature are acceptable.
No Check power dissipation Yes
and surface temperature.
Excessive?.

Done
Manual Inductor Design : Area-Product Method

• Assemble design inputs and compute required L IrmsIp rating

• Choose core geometry, core material, and winding conductor
geometry.

• Use L IrmsIp = kcu Jrms Bac Aw Acore to find the required area
product Aw Acore and thus the core size.
• Assume Jrms= 2-4 A/mm2 and Bac = 50-100 mT.

• Complete design of transformer as indicated.

• Check power dissipation and surface temperature using

assumed values of Jrmsand Bac. If dissipation or
temperature are excessive, select a larger core size and repeat
design steps until dissipation/temperature are acceptable.

• Set airgap to achieve Bp at Ip and adjust A and N if needed.

 Critique of Area-Product Method

• Procedure ignores dependence of J and B on core size.

• Assumed values of J and B are smaller than necessary for components with small electrical ratings
and results in overly large components for the small electrical ratings range.
• Assumed values of J and B are larger than allowable for components with large electrical ratings
and results in components that are too small for the large electrical rating range.

• Large number of cores and core materials available makes it difficult for inexperienced designers to
make a reasonable first choice of core and core material for a particular application. Results in multiple
manual and time-consuming design iterations.

• Comparison of designs using different core geometries and materials (highly desirable if the smallest
sized component is to be found) impractical.
• Requires detailed information on all cores and core materials of interest which may be difficult to
find in a short time.
• Requires many lengthy manual(and hence error-prone) calculations.

• Manual area-product procedure best suited for one-off design situations or where rapid construction
and testing is more important than cost, size, or weight considerations.
 Relating J and B to Core Size Quantitatively
• Assume simple thermal model of transformer (core+winding).
1. Losses uniformly distributed over entire transformer volume. P sp,core = Psp,winding = Psp
2. No significant temperature gradients in transformer interior. Tinterior ≈ Tsurface = Ts
Ts - Ta
• Psp = R ; R,sa = h/As
,sa(Vw + Vc)
• h = convective heat transfer coefficient = 10 C-m2/W B
• As = surface area of transformer (core + winding). Estimate Bs

using core dimensions and s imple geometric considerations. Minor

• Uncertain accuracy of h and o ther heat transfer parameters do hystersis
not justify mo re exact the rmal modeling o f transformer. loop

Psp H
• Psp,co re = Psp = k cu cu (Jrms)2 or Jrms = kcu cu

[Psp]1/b - Bs
• Psp,co re = Psp = K c fa [ Bac]b or Bac =
[Kc]1/b[f]a/b
• Kc,a,b = constants of selected f errite material.
 Example: E-core Geometric Parameters

• E-core dimensions • Winding area Aw = 2D(E-F)/2 = D(E-F)

• Two core halves make up a complete
double-E core.
• Core volume Vm, core area Am, and mean
path length lm given in core spec sheet.
• Winding volume Vw, winding area Aw, and
mean turn length lw without coil
former generally not given.
• Mean turn length lw = 2(F+C)+0.5π(E-F).
See figure to left.
• Winding volume Vw = Aw lw
• Similar formulas for all cores in database.
• Winding parameters of coil formers used
in spreadsheet where available.
 Example: E-core Transformer Surface Area As

2B C
1 • As = surface area of
(E-F)
2 assembled core plus surface
area of winding not included
A in core surface area.

• Core surface area

A E
= 4AB + 4BC + 2AC

• Surface area of winding not

included in co re surface area
= 4E{0.5}(E-F)+
Rounded corners 4{2D(0.5)(E-F)}
ignored in surface = 2E(E-F) + 4D(E-F)
area estimate = 2(E-F)(E+2D)

1 • As = 4AB + 4BC + 2AC +

(E-F)
2 2(E-F)(E+2D)
2D
 Spreadsheet-based Interactive Core Database
• Spreadsheet offers ideal way to calculate core ratings and associated design parameters.

• Complete information on core parameters (dimensions, areas, thermal resistance, etc.) and ferrite
material parameters (core loss) pre-stored in spreadsheet for all core and material types of interest.

• User enters input specifications from converter design requirements.

• Spreadsheet calculates capability of all cores in database and displays smallest size core of each
type that meets transformer V- I or inductor LIrmsIp specifications.

• Also calculates and displays design output parameters including Jrms, B, Acu,pri, Acu,sec, Npri, Nsec,
leakage inductance, and efficiency of transformer or equivalent parameters for inductor.

• Multiple iterations of core material and winding conductor choices can be quickly done to aid in
selection of most appropriate tranformer/inductor design.

• Graphical capabilities of spreadsheet allow graphical data presentation if desired.

• Ability to compare different cores and core materials for same application limited only by number
of cores and materials entered in the database.
 Example: Pre-Stored Potcore Parameters in Database
Phillips w/bobbin w/bobbin
2 3 2 3 2
designation [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm ] [mm ] [mm] [mm ] [mm ] [mm ] [ C/W]
Core # Dim. A Dim. B Dim. D1 Dim. D2 Dim. D3 Dim. D4 Dim. H1 Dim. H2 Lm Ac Vc Lw Aw Vw As R
P7/4 5.5 1.6 7.4 5.8 3.0 1.4 4.2 2.8 10.0 7.0 70.0 14.6 2.2 31.4 125.0 1066.9
P9/5 6.5 2.0 9.3 7.5 3.9 2.1 5.4 3.6 12.5 10.1 126.0 18.8 3.4 64.1 200.9 663.6
P11/7 6.8 2.2 11.3 9.0 4.7 2.2 6.5 4.4 15.5 16.2 251.0 22.7 4.8 108.3 294.5 452.8
P14/8 9.5 2.7 14.3 11.6 6.0 3.1 8.4 5.6 19.8 25.1 495.0 29.0 8.7 250.9 479.4 278.1
P18/11 13.4 3.8 18.4 14.9 7.6 3.1 10.6 7.2 25.8 43.3 1120.0 36.7 18.1 664.3 781.7 170.6
P22/13 15.0 3.8 22.0 17.9 9.4 4.4 13.4 9.2 31.5 63.4 2000.0 44.7 27.1 1211.4 1167.7 114.2
P26/16 18.0 3.8 25.5 21.2 11.5 5.4 16.0 11.0 37.6 93.9 3530.0 52.7 39.3 2071.1 1606.2 83.0
P30/19 20.5 4.3 30.0 25.0 13.5 5.4 18.8 13.0 45.2 137.0 6190.0 66.0 58.1 3834.6 2221.0 60.0
P36/22 26.2 4.9 36.2 29.9 16.2 5.4 21.7 14.6 53.2 202.0 10700.0 74.3 72.4 5379.3 3121.8 42.7
P42/29 32.0 5.1 42.2 35.6 17.7 5.4 29.4 20.3 68.6 265.0 18200.0 86.0 140.0 12040.0 4786.2 27.9
P66/56 7.0 66.3 53.5 28.8 6.4 55.8 42.0 123.0 717.0 88300.0 130.0 400.0 52000.0 13814.4 9.7

• Winding window parameters Lw, Aw, and Vw based on use of coil former or bobbin.
• Each core geometry has a separate worksheet similar to the potcore sheet shown above.
• E coress
• EC cores
• EFD cores
• EP cores
• EP cores
• ER cores
• ETD cores
• PM cores
• Potcores
• PQ cores
• RM-I cores
• U cores
 Ferrite Materials in Spreadsheet Database
Ferrite Material Parameters

MANUFACT. SUGGESTED
Bsat MAX FREQ MATERIAL Kc a b µ a/µ o
[mT @ 100 ºC] [kHz] C(T) SIEMENS
370 1000 0.74353 N27 2.1566E-05 1 2.34 5000
350 1000 0.62004 N41 1.66E-04 1 1.98 4800
300 2000 0.79307 N49 1.2322E-06 1 2.89 2100
360 1000 1.058 N53 2.6E-06 1 2.666 4300
310 3000 1.01975 N59 5.66E-06 1 2.7926 1700
320 1000 0.66403 N61 1.26E-05 1 2.420 3600
340 1000 1.04602 N62 9.92E-07 1 2.808 4600
380 1000 1.25767 N63 1.9E-06 1 2.757 4700
340 1000 1.1317 N67 9.8288E-07 1 2.851 4300
330 1000 0.7942 N72 6.20E-07 1 2.869 4000
340 1000 1.2119 N87 4.12E-07 1 3.00 4600
PHILIPS
320 1000 0.7098 3B8 7.10E-07 1.6 2.5 4000
350 1000 1.19713 3C15 1.20E-07 1.7 2.8 5000
350 1000 1.416 3C30 4.25E-07 1.5 2.7 5000
310 100 1.0033 3C80 9.63E-06 1.42 2.2 4000
320 1000 0.6658 3C81 7.99E-07 1.56 2.55 5500
310 2000 1.0999 3C85 4.95E-07 1.6 2.6 4000
330 1000 1.1194 3C90 5.60E-07 1.5 2.6 5500
330 1000 1.1423 3C94 1.60E-07 1.6 2.7 5500
330 2000 0.9167 3F3 1.38E-06 1.3 2.5 4000
350 3000 0.9678 3F35 1.19E-08 1.5 3.52 2500
310 5000 0.8455 3F4 1.73E-07 1.35 3.11 1700
180 10000 0.88 4F1 1.58E-05 1.35 2.25 300

Transfer Data

330 21 1.5992E-07 1.6 2.7 5500

 Details of Interactive Transformer Core Database Calculations

• User inputs: Vpri, Ipri, Vsec f, Ts, Ta, and kcu for transformer; L, Irms, Ip, f, Ts, Ta, and kcu for inductor.

• Stored information (static, independent of converter requirements)

• Core dimensions, Aw, Acore, Vc, Vw, surface area, mean turn length, mean magnetic path length, etc.
• Quantitative core loss formulas for all materials of interest including approximate temperature dependence.

• Spreadsheet calculates capabilities of all cores in database

1. Converter-required transformer V-I rating = Vpri Ipri or inductor stored energy rating = L IrmsIp.
2. Compute allowable specific power dissipation Psp = [Ts - Ta] /{ Rsa [Vc + Vw ]}. Rsa = h/As
3. Compute allowable flux density Psp = k fb [Bac]d and current density Psp = kcu cu {Jrms}2.
4. Compute core capabilities 4.4 f kcu Aw Acore Bac Jrms (transformer) or kcu Aw Acore Bp Jrms (inductor)

• Calculation of transformer parameters.

1. Number of primary turns Npri = Vpri /{2π f AcpreBac} and secondary turns Nsec = Vsec /{2π f AcpreBac}
2. Winding conductor areas assuming low frequencies or use of Leitz wire
• Acu,pri = [kcuAw]/[2 Npri] and Acu,sec = [kcuAw]/[2 Nsec]
 Details of Interactive Transformer Core Database Calculations (cont.)

. 3. Leakage inductance Lleak= {µo{Npri}2 lw bw}/ {3 p2 hw} (E-core formula): Similar formulas for other cores.

• Calculation of inductor parameters

1. Conductor area Acu= Irms/Jrms; number of turns N = kcuAw/ Acu
2. Set airgap length so that at Ip total flux density = Bp. Assume effectivedimensions of gap area equal dimensions
of core plus g, where g is the airgap length.

• Spreadsheet examines capabilities of all cores and displays the smallest size core of each different geometry that
meets the requirements on the input-output page (INOUT) of the spreadsheet.

• Transformer outputs: core number, current and flux densities, total volume, conductor areas, number of primary
and secondary turns, leakage inductance, and efficiency (power out)/(power in).

• Inductor outputs: core number, current and flux densities, total volume, conductor area, number of turns, and
airgap length.
Input - Output Section of Inductor Design Tool
Design
Inputs

Inductance Idc Iac(b-p) Ipeak Irms LIpIrms

kcu Ta ( C) Ts (C) Freq. [kHz] Material [µH] [A] [A] [A] [A] [milliJoules]  [mm]
0.4 35 70 40 3F3 39 0.001 6.700 6.701 3.868 1.01 0.37314377
40 0 67
3F3
Trianglar
Waveform
Assumed for
AC current

DESIGN
OUTPUTS

Skin, Prox.
Core Type Core # LIpIrms Jrms Bpeak N Acu Airgap Effects? Vc+Vw
2 2 3
[milliJoules] [A/mm ] [mT] [#] [mm ] [mm ] [cm ]
E-core E25/13/7 1.12 3.55 211.49 21.97 1.09 1.15 YES 6.47
EC-core EC35 2.26 3.28 199.54 15.54 1.18 0.61 YES 11.97
EFD-core #N/A 0.00 #N/A #N/A #N/A #N/A #N/A #N/A #N/A
EP-core #N/A 0.00 #N/A #N/A #N/A #N/A #N/A #N/A #N/A
ER-core ER28L 1.37 2.27 151.76 21.16 1.70 1.44 YES 12.55
ETD-core ETD29 1.71 3.10 191.00 18.00 1.25 0.93 YES 10.41
PM-core PM 50/39 12.38 2.33 154.81 4.56 1.66 0.20 YES 75.41
Potcore P30/19 1.36 2.57 166.47 11.46 1.50 0.66 YES 10.02
PQ-core PQ26/25 1.39 2.41 193.56 11.25 1.60 0.49 YES 9.21
RMI-core RM10/I 1.21 3.51 209.65 12.90 1.10 0.54 YES 6.54
U-core U20/16/7 1.18 3.32 201.28 23.19 1.16 1.10 YES 8.09

Notes

Any row having multiple cell entries of #N/A indicates the core in

that row cannot meet the input specifications. Cell entries with

negative numbers or #NUM! Indicate numerical problems in the calculations

for that cell. Entries in such cells should be ignored but the rest of

the entries in that row are still reliable. Airgap calculations are

the most likely to have problems.

Input - Output Section of Transformer Design Tool
Design
Inputs

Throughput
kcu Ta (ºC) Ts (ºC) Freq. [kHz] Material Vpri,rms Ipri,rms Vsec,rms Isec,rms Power  [cm]
0.67 24 93 101 3C94 107 10.0 110 9.73 2140 0.02348256
67 100
3C94

Design Outputs

Skin, Prox. [nH]

Core Type Core # V-A Rating Jrms Bac Npri Nsec Acu,pri Acu,sec Effects? Vc+Vw Lleakage Efficiency
2 2 2 3
[watts] [A/mm ] [mT] [#] [#] [mm ] [mm ] [cm ] [%]
E-core E41/17/12 2665 3 135 11.4 11.7 3.26068 3.1717523 YES 22.9 167.2 99.70%
EC-core EC41 2283 3 142 13.9 14.3 3.0705642 2.9868215 YES 19 141 99.72%
EFD-core #N/A 0 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A
EP-core #N/A 0 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A
ER-core ER40 2142 2 104 15.4 15.8 4.654855 4.5279045 YES 30 182 99.81%
ETD-core ETD39 2459 3 129 14.7 15.2 3.4657303 3.3712104 YES 24 183 99.73%
PM-core PM 50/39 7578 3 117 5.5 5.6 3.9545774 3.8467253 YES 75 90 99.34%
Potcore P42/29 2901 2 111 8.1 8.3 4.2421993 4.126503 YES 30 104 99.77%
PQ-core PQ35/35 3243 3 119 10.6 10.9 3.8835429 3.7776281 YES 30 124 99.72%
RM-I core RM14/I 2721 3 135 8.9 9.1 3.2577377 3.1688903 YES 22 79 99.72%
U-core U/33/22/9 2679 3 123 22.3 23.0 3.693498 3.5927662 YES 37 1030 99.63%

Notes

Any row having a cell entry of #N/A indicates that the

core in that row cannot meet the input specifications.

Typical User Interaction With Spreadsheet

• Spreadsheets do not take skin effect and

proximity effect into account.

• User can either use Leitz wire or use

the iterative conductor selection process
described in the textbook.
 Other Suggested Uses of Spreadsheets

• Core capability versus frequency at fixed temperature. (Example given on next slide)

• Core capability versus temperature at fixed frequency.

• Core capability versus size (volume or weight).

• Material performance factors versus frequency. (Example given in following slides.)

• Effect of different core materials on a specific component design.

• Spreadsheet graphing capabilities very useful for presenting output data in clear graphical format
instead of harder-to-understand numerical tables. Examples given in next two slides.

• Users familiar with EXCEL can easily modify spreadsheet to automate calculations such as those
mentioned above as well as others.
Example: E Core V-A Capability vs Frequency

• Curve labels refer to Phillips E core designations.

• 3C80 ferrite ; DT = 65 oC ; kcu = 0.2
Example: Selected Material Performance Factors