Beijing institute of technology, 1995 a thesis submitted in partial fulfillment of the requirements for the degree of master of science in the department of electrical and computer engineering in the college of engineering and computer science. After that fem simulators are introduced to numerically compute the winding loss. Sep 23, 2003 in this work, the particular problems raised from parallel winding are addressed and modeled based on a onedimensional field model. The transformer was analyzed without the core and with the core. While there are many transformer design programs out there, we have out together a list of the top six solutions we believe are the best for. Such software is among the familiar tools of the designer and.
Denote the voltseconds applied to the primary winding during the positive portion of v1t as 1. You can experiment with the number of turns, dcr and the location of. In the good old times it was a matter of fact that every electronic hobbyist or technician would wind himself any power transformers he needed, and rewind any that burned out. A complete electrical circuit of a transformer is formed by windings. Windings of primary and secondary coils are printed on both sides of pcb. The design uses 12layer winding incorporating a primary and secondary winding produced using 2 oz.
The model will give you a blueprint of the conceptual results, way before you start investing money and resources in the actual construction of the transformer. Additionally, the main manufactured elements a coil made of pcb winding and ferrite magnetic core are collected. Aerospace planar transformers for switchmode power. A java utility for generating obround or quadrilateral planar transformer winding footprints in either geda footprint or kicad legacy module format. Software to predict the current density distribution and ac loss for planar windings has been developed. Excellent reproducibility, enabled by winding structure in transformer applications, the winding configurations commonly employed in planar devices are advantageous in reducing ac winding losses. You can experiment with the number of turns, dcr and the location of the windings within the assembly interleaving. Hinged planar components they are closest to the conventional inductive components. Ies has helped the power and distribution, and manufacturing industries for decades, solving complex design challenges in an effort to make power systems and their components more. Planar transformer request form we meet each unique need, encompassing our global capabilities to partner, solve, and deliver custom engineered solutions. Measurements on planar e core transformers under operating conditions with windings in multilayer pcbs show that the thermal resistance is substantially lower. How to design an rf planar transformer with 2 tapped winding. The planar transformer pcbs form a split primary winding enclosing the secondary made from triple insulated wire. Leakage inductance measured between pins 2 and 4 at 100 khz, 0.
Design of planar power transformers elna magnetics. By using this website you agree to the placement of cookies. Coreless planar transformer using lowtemperature cofired ceramics for isolated gate driver applications matthew w. Magnetics designer is a standalone software program for windows that designs all types of layer and sectorsplit bobbin wound transformers and inductors, and generates a corresponding spice model. Because of the limited available winding space it is recommended to use the maximum allowed flux densities in planar magnetics. Planar transformer winding technique for reduced capacitance in llc power converters conference paper pdf available september 2016 with 1,127 reads how we measure reads. Unfortunately, nowadays transformer winding is fast becoming a lost art, and i have seen many people despair about where to find some very. In todays highfrequency lowprofile switchingmode power converters, paralleling winding in planar transformers is needed, especially for low voltage and high current applications. Software tool for designing flyback transformers based on planar cores.
Introduction to planar magnetic pcb design terratel. Current sharing between parallel turns of a planar. A compact planar transformer of a new design was analyzed in this paper. Magnetic builder is a useful magnetic design software. Also, the winding can be made of multilayer circuit boards. Consequently, a software platform for magnetics design is established. Download transformer calculator coils and wire thickness.
It also enables direct integration to circuit simulation tools. The transformer is one of the fi rst critical components in the. Planar transformers are high frequency transformers used in isolated switchmode power supplies operating at high frequency. Less ac winding resistance excellent reproducibility, enabled by winding structure in transformer applications, the winding configurations commonly employed in planar devices are advantageous in reducing ac winding losses. Planar magnetics design for lowvoltage dcdc converters. The planar transformer height effect on the power density was studied. Aerospace planar transformers for switchmode power supplies. The switch mode converter and the planar transformer showed a high efficiency of 90 and 99% at 2 mhz operating frequency, respectively. Transformer design software integrated engineering software.
Design, modeling, and analysis of a compact planar transformer. Magnetics designer produces a complete transformer or inductor design based upon electrical specifications, including a winding sheet report and a spicecompatible model with parasitics. A planar transformer, the primary component used in switchmode power supplies, offers volumetric efficiency and a lower profile over traditional wirewound transformers because it uses printed. Model and design of pcb parallel winding for planar. Inductance measured on an agilenthp 4284 between pins 2 and 4 at 200 khz, 0. The user can quickly and easily generate a helical, obround, square, or rectangular pcb winding of specified dimensions using command line options. The benefits of planar magnetics in of power conversion. Magnetic builder magnetic design software, inductor and. Standard transformer typical planar transformer copper area window area, wa ku 0. May 27, 2016 for the love of physics walter lewin may 16, 2011 duration.
Standard part numbers are available of the shelf, and customized quickturn prototypes are available in a. We changed the voltage ratio by using different seriesparallel connections. Using ferritic core, the inductance was increased for 22% in comparison with coreless transformer. This means that, for a given alternating current ac power supply that switches back and forth between forward and reverse current, the current in both the primary and secondary windings are in sync with one another during this dynamic. Htlt powerdistribution transformer design software. How to calculate the winding of a transformer sciencing. The basic step to building a transformer is to create the model of the object. Model and design of pcb winding parallel for planar. The design of a multilayer planar transformer for a dcdc. Manual design techniques have become obsolete even the third world countries are using the latest software solutions for transformer design. This integrated planar transformer consists of a main transformer board sandwiched between two small winding boards, in a ferrite ei core.
When comparing a standard transformer with a planar transformer there are actual four different points of comparison. Magnetics designer produces a complete transformer or inductor design based upon electrical specifications, including a winding sheet report and a spicecompatible model. The window utilization, ku, comparison of the two different winding techniques is shown in figure 2012. Primary windings has two turns wp 2 and the secondary has 96 turns ws1ws2ws3 96. Unlike conventional wirewound inductive components windings of inductors based. The cross sectional area of the magnetic core and of the winding window, also the total copper area after applying the fill factor, the turns per volt constant that will be valid for all windings on this transformer, and the average. Evanscores or 5leggedcores usually consist of several individual bodies with different shapes. Figure 2 shows the winding arrangement of high voltage planar transformer.
Three different schematics and 15 turns ratios to meet a variety of applications. Calculating performance of planar magnetics 2 the transformer consisted of four windings having eight layers and 38 turns total. The transformer winding formula only holds true when the angles of primary and secondary windings are in phase with one another. However, in inductors and flyback transformers using gapped centerlegs, the winding configuration often results. Software to predict the current density distribution and ac loss for planar windings. Salient features of ht transformer design software packages. The figure clearly shows that, as the transformer height increases from 0.
Design, modeling, and analysis of a compact planar. Pdf this paper presents a new design of a planar transformer. What is magnetic builder inductor and transformer design tool. Inhouse the design engineer can adapt the different combinations of serial and parallel configurations of the windings to give a substantial number of ratio and current possibilities via the supplied software. The devices unique design can be optimized for customerspecific switching frequencies, input and output voltages, and current levels. Designing the winding structure sets the criteria for the needed window, which results in selecting a bigger core than initially needed. Winding arrangement of high voltage transformer figure shows pcb stack up implemented in ecore. Designing a planar transformer and using the pc winding technique, reduces the window utilization factor even further. A multilayer planar transformer the geometry of the analysed multilayer planar transformer with fundamental dimensions is presented in figure 1. Transformer losses should be examined under worstcase conditions that the power supply is expected to operate over long periods of time, not under transient conditions. Coreless planar transformer using lowtemperature cofired. The model provides a simpler method to derive the core and winding loss of the transformer than using a finiteelement analysis software.
A prototype planar pcb transformer was used to obtain experimental data for model validation. Although this practice is believed to be effective to increase the current handling capacity of the windings, the effect might be offset due to the unequal current sharing within. Model and design of pcb winding parallel for planar transformer. The bodies are manufactured by winding thin electrical steel foils on a mandrel. Download transformer calculator coils and wire thickness at. Magnetics designer produces a complete transformer or inductor design based upon electrical specifications, including a winding sheet report and a. This relation can be used to estimate the temperature rise of the transformer as a function of flux density in the core. Join date jul 2002 location middle earth posts 4,629 helped 494 494 points 36,491 level 46. This planar transformer was used in a flyback switchmode dcdc converter with a pulse width modulator feedback control circuit.
For the love of physics walter lewin may 16, 2011 duration. The user can quickly and easily generate a helical, obround, square, or rectangular pcb winding. Magnetics designer software makes transformer and inductor design easy. Topic 4 designing planar magnetics texas instruments. It is a tool for user to create hisher own magnetic component inductor and transformer by selecting different ferrite core, bobbin type and winding method. Transformer winding must be electrically and mechanically strong to withstand overvoltages under transient surges. They are placed between the smallsized ferrite cores. The planar transformer pcbs form a split primary winding enclosing the. In the design of these kinds of wide band rf transformers the primary reactance is usually around 5 times the primary impedance.
Planar cores, ferrite planar cores, software tool for. High efficiency low losses, ultra compact, lowprofile. The unique 025 2100 planar transformer product line of custom planar transformers come in standard sizes and with hundreds of lead frames and pcb windings in stock, they can be quickly customized often without startup or tooling costs for many power topologies, including soft switching. Transformer losses can be put into three major categories. Model and design of pcb parallel winding for planar transformer. The first two lines of the orange output area of my spreadsheet show some basic results for that transformer. With the assumption that half of the total transformer. May 29, 2015 a planar transformer, the primary component used in switchmode power supplies, offers volumetric efficiency and a lower profile over traditional wirewound transformers because it uses printed. Rm here the core shapes are different in standard sizes. Relatively planar transformer design, can be divided into several types. From the time the first software appeared on the market, until this very day, the demand for the program continues to increase. Planar technology is a relatively modern process that allows transformers to operate at a high frequency unlike the conventional wirewoundonabobbin transformers, planar transformers use flat windings, usually on a printed circuit board or insulated copper plates, instead of copper wire to form the coils. Achieving higher ethciency using planar flyback transformers. Transformer winding construction should ensure safety under normal and faulty conditions.
The hybrid planar transformer series is available in surfacemount and throughhole configurations. The design and development of a novel flyback planar. In this paper, the most important factors for planar transformer pt design including winding loss, core loss, leakage inductance, and stray capacitance have individually been investigated. Transformer analysis is one of the most widely used applications for our electromagnetic simulation software, and our customers depend on accurate, reliable results. Planar pcb transformer model for circuit simulation ieee. View the kit manual this is the kit used by coilcraft designers to provide fast turnaround of planar transformer samples. Chapter 20 planar transformers university of north. However, in inductors and flyback transformers using gapped centerlegs, the winding configuration often results in greater ac winding loss. With a 200 ohms to 50 ohm transformer, we would allow a reactance of 1,000 ohms at the lowest frequency of interest. To order a transformer with an optional auxiliary winding, add an x and the turn count after the pl140, e. W e offer engineered planar magnetics solutions for a broad spectrum of product applications in all major markets.
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