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Design of APFC Inductor Utilizing Powder Cores

Design of APFC Inductor Utilizing Powder Cores

Abstract: Magnetic powder core has higher saturation flux density and better DC bias static linearity . When used to make APFC inductors, only by appropriately selecting the core size and the number of coil turns can the effect of reducing core loss be achieved.

Abstract: Powder core has high saturation flux density and excelRwandans Sugardaddylent motion linearity of DC bias.When powder core is used to prepareon of APFC inductor, lower core loss will be obtained as long as core sizes and coil turns are properly selected.

Keywords: saturated DC biasRwanda SugarMagnetic core loss static linearity

Keywords: Saturation, DC bias, Core loss, Motion linearity.

The saturation flux density of magnetic powder core is as high as 10T (10000Gs) or so, under strong magnetic field conditions, that is, when working at high current, the magnetic core is not easy to saturate. Making APFC inductors does not require an air gap and will not cause electromagnetic interference (EMI) to the circuit. And because its DC bias magnetic static linearity is quite good, the inductance value at the rated current can be accurately controlled through design calculation. Proper selection of the core size and the number of coil turns can also achieve satisfactory core loss results.

Rare magnetic powder cores include molybdenum permalloy magnetic powder core (MPP), high flux magnetic powder core (HF), iron silicon aluminum magnetic powder core (MS) and iron powder core (IP). The first two are conventionally called iron-nickel-molybdenum magnetic powder cores and iron-nickel magnetic powder cores. Their core loss data are shown in Table 1. The first three are products of the American Arnold Group (ARNOLD), and the latter one is a product of Japan. It can be clearly seen from Table 1 that the MPP core has the lowest loss, the iron powder core has the highest loss, and the other two are in the middle. Under certain conditions, the MS core loss is slightly lower than the HF core and close to the MPP core.

MPP cores are relatively expensive, and there is a conflict between low loss and high cost. When the temperature rise must be very low, this more expensive core has to be used. For occasions where the requirements are not particularly stringent, it is completely possible to use other magnetic cores through special design, or even use high-loss iron powder cores, and still achieve satisfactory results.

1 Analysis of parameters related to inductor design

For the design and production of APFC inductors, it is important to require low temperature rise (that is, small losses), and other small bias magnetic effects, which can Effectively control the inductance value not to be lower than the critical inductance value at the rated current.

In order to design an APFC inductor with satisfactory performance and cost performance, it is necessary to conduct a sufficient analysis of the relevant parameters of the inductor design.

Some parameters are related to core specifications and sizes, such as: AL, Ae, le, Ve, Wt, l/N, SA, Wa, etc. H/NI is derived from le, which is equal toAt 0.4π/le, it can be called the magnetic field intensity coefficient. The larger the magnetic core, the larger the le, and the smaller the value. Multiplied by NI is the magnetic field strength value H. In addition, it can also be called the saturation coefficient. If this value is small, it is not easy to saturate. When similar to NI, a large magnetic core is less difficult to saturate than a small magnetic core. There is another parameter: the number of coil turns N. The more turns, the greater the inductance value. l/N is the uniform length of each turn of wire, and the unit is cm. SA is the overall area of ​​the coil. AL is the inductance coefficient, and the unit is nH/N2 or μH/N2. There is such a relationship between inductance and effective magnetic permeability: AL=μe·4π·Ae/le. The relationship between the inductance coefficient, the number of turns and the inductance is: L=N2·AL.

It is relatively simple to control core saturation, which is to choose a large core size and use materials with low magnetic permeability. It can be seen from Rwandans Escort Figures 1 to 4 that the low magnetic permeability curve tends to decrease as the magnetic field intensity increases. , relatively stable and slow (Note: The coordinate in the original manuscript is called “percent magnetic permeability”, which is represented by the absolute magnetic permeability μr ).

Table 1 Magnetic powder core core loss (unit: mW/cm3)


6.44×10-10f1.18(Hz)B2.27(Gs)

Note: Figure The value of the abscissa in the middle uses Oe as the unit, which does not comply with the statutory unit. It is now converted to A.cm-1,1Oe=0.796A.cm-1

Hyf1 .gif (24849 bytes)

Figure 1MPP absolute magnetic permeability (μr)—DC magnetic field strength (H ) Characteristic curve

Hyf2.gif (18840 bytes)

Figure 2HI—FLUX absolute magnetic permeability (μr)—DC magnetic field strength (H) characteristic curve

Hyf3.gif (32387 bytes)

Figure 3SUPPER—MSS absolute permeability (μr)—DC magnetic field strength (H) characteristic curve

Hyf4.gif (149439 bytes)

Figure 4 Absolute initial magnetic permeability (μr)-DC magnetic field strength (H) relationship curve

There are many parameters related to core loss, which provide us with There is room for adjustment. There are two formulas: Pcore=kfmBn and Bac=(L△I·102)/2AeN. The former equation states that core loss is inversely proportional to frequency and flux density. When the frequency is certain, the magnetic flux density is small and the loss is small. It can be seen from the latter formula that when the numerator value remains unchanged, increasing the denominator value, that is, increasing Ae or N, or increasing the product of the two, the Bac value will decrease. Increasing the N value will increase copper loss and magnetic field strength, and must be handled appropriately. If materials with low magnetic permeability are used, the increase in N will neither increase the inductance nor cause μr to decrease more due to the increase in magnetic field intensity. Increasing Ae will reduce the number of turns due to the increase in AL value, but only the product of the two increases. For example, if Ae is doubled, AL is also doubled, but N is only reduced by 30%. The product of Ae and N can be increased by 40%, resulting in a nearly 30% decrease in Bac. Therefore, as long as the relevant parameters are adjusted appropriately, satisfactory design results can be obtained.

2 A design example

Design a 2000W inductor. Uo=400V, eta=95%, f=100kHz, Ui(aRwandans Sugardaddyc)min=90V. Set △I to 0.2Ii. The critical inductance value is obtained from the following formula: Select the required core through the following relationship.

LI2=(NI)2AL′μrμ

After moving the terms, we get AL′=LI2/(NI)2μr(2)

It can be found from Table 2 Different magnetic cores have different NI values ​​of μr. Now select μ as μr=50%. Substitute a certain magnetic core coherence number into the above formula to obtain the AL′ value. Divide this value by the AL value of this core to determine how many cores to use.

(1) Use ARNOLDMPP magnetic core 866142, NI of μr=50% is 733 and substitute it into the formula to get AL′:

AL′=(132×36.32)/(73Rwandans Sugardaddy32×0.5)=0.647

Table 2 NI values ​​when several magnetic powder cores are different from μr


This result obviously cannot be adopted.

(2) Select ARNOLDMPP core 123068, and the NI of μr=50% is 1560. Substitute into the formula to get AL′ as 0.143, 0.143/0.068=2.1. It can be used with 2 magnetic cores. Both are applicable, and some parameters need to be modified as follows:

AL=0.136μH/N2, Ae=3.54?;Ve=69.54?;

l/N=8.79cm;SA= 259?.

Set μ=50%, the starting inductance value is:

132/0.5=264μH, N=44, Lo=263.3μH,

NI=44 ×36.3=1597.2,

H=1597.2×0.0641×0.7958=81.5A/cm

Check the curve and get μr=49%.

L31.3=263.3×0.49=129μH≈132μH

The next step is to calculate the core loss: Pcore=0.7066×1001.483×0.278241.889=58.3Rwandans EscortmW/cm3 The above results are quite satisfying.

Since MPP cores are more expensive, can iron powder cores be used instead? You can choose a few magnets and do the math.

(3) Use iron powder core T30052, NI is 1008 when μr=50%. Substituting into the formula, we get AL′ as 0.342, and its AL is 0.080, 0.342÷0.080=4.3. Even 4 animals are needed, which is not advisable.

(4) Use iron powder core T30018, NI is 1512 when μr=50%. Substituting into the formula, we get AL′ as 0.152, and its AL is 0.058, 0.152÷0.058=2.6. You can try it with 3 pieces. 3 are shared, and the parameter adjustment is:

AL=0.174μH/N2; Ae=5.04cm2; Ve=100.2cm3;

l/N=13.05cm; SA=273cm2.

Set to μr=50%, and the starting inductance value is 264μH.

N=38.9≈39, Lo=264.6μH, NI=1415.7, H=71.6A/cm, μ=52%, L36.3=264.6×0.52=137.6μH>132μHPFe=106.74×100.2 =10691.34mW The temperature rise is 15.6℃ higher than that of MMP, so it can still be used.

3 Effects of adjusting parameters

The following four types of cores set μr at 50%.Just choose two of the 4 types. What will be the result if μr is adjusted to 40% or 30%? Table 3 lists the core calculation results for seven types of cores positioned at μr=30%. In addition to 866142 requiring 4 pcs, 488075 using 3 pcs can also achieve a temperature rise of 41°C. The temperature rise of HF300060 is only 30°C when using one piece, while the temperature rise of MS300060 is only 28°C when using two pieces. Iron powder core T30052, using only two Rwandans Escort, the temperature rise is 53℃, and two T22518, the temperature rise is slightly higher. 61℃. T30018, 3 pieces are needed, the temperature rise is 42.4℃, see 2(4) above (when μr=50%).

You can choose at least 3 of the 7 types of magnetic cores. There are two types with a temperature rise of more than 50°C. There are two types that require more than 3 types. You can choose them. Table Rwanda Sugar4 shows the characteristic parameters of several magnetic cores for reference. The last two columns are the number of turns that can be wound on #8 and #7 copper wires with a winding fill factor of 40%. In actual application, more than 20% is still manageable.

4 Conclusion

The above design ideas first solve the problem of saturation effect, which can ensure that the inductance is not lower than the critical inductance value when the extra current is applied. Then take another step to calculate the temperature rise. During specific operation, you can take the steps in Table 3 to list all the magnetic cores that can be selected. After calculating the results, choose the one with low temperature rise and low price. What kind of magnetic core can be selected? According to this example: Po=2000W, f=100kHz, Uo=400V, eta=95%, Ui(ac)min=90V. As shown in Table 2, if the NI reaches about 2,000, it will basically work. Fundamental power factor correction below 1000 uses inductor data


Basically it is not possible. Conditions have changed, especially power and frequency, which have changed even more. APFC inductors have a special feature. The iron loss is generally low due to the large number of N, and the copper loss is often higher than the iron loss. Therefore, when the copper wire can be wound, making the wire diameter as thick as possible can reduce copper loss. The previous examples all use #8 copper wire, while the cores in Table 3 use #7 copper wire. If #7 copper wire is used in the previous example, the temperature rise will decrease by 3.6℃ and 4.2℃ respectively.


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Thank you! 2015-01-17 12:00:17 Why does the motor excitation show inductance characteristics instead of resistance characteristics? 2023- 12-21 08:00:36 Why is the extra current of the ferrite inductor smaller than that of the magnetic bead? `2011-10-16 20:15:06 Do you know the body? Material? The inductance of the coil is widely used. The main materials as the core include silicon (or silicon) steel sheet, permalloy, ferrite, copper and air. . Common iron cores are mainly made of silicon steel sheets; magnetic cores and magnetic rods are generally made of ferrite and other materials. -Gujing Electronics Suzhou Gujing Electronics specializes in inductor manufacturers. It has 16 years of experience in the industry. It has complete specifications, fast delivery, and provides specialized technical support. Last month, a customer came to pursue a magnetic ring inductor coil. , Gujing’s magnetic toroidal inductors can be customized due to different parameters, sizes and other reasons. What this customer needs is not 2020-06-08 15:50:28 Advantages of Beijing customized inductors – plug-in inductors – magnetic ring inductors provide high-standard, high-tool quality inductor products to meet the needs of different customers. At the same time, we have gained great experience and breakthroughs in customized inductor products. Rwanda Sugar Daddy can provide special product customization services according to customer needs. A customer used to pursue a magnetic toroid inductor coil, and the customer’s demand was no exception. 2020-09-02 13:18:53 Beijing plug-in inductor-inductor customization-magnetic toroid inductor may require a magnetic toroid inductor. Due to the design of the board, the plug-in magnetic ring inductor cannot be used on the customer’s board, soAdopt flat type. The flat-mounted inductor has relatively high process requirements and requires shaping, and the two pins must be on the same plane. If the processing is not in place, it will be wasted. So 2020-08-11 08:34:11 Beijing plug-in inductor – inductor customization – magnetic ring inductor to magnetic ring inductor. Due to the design of the board, the plug-in magnetic ring inductor cannot be used on the customer’s board, so a flat-mounted one is used. The flat-mounted inductor has relatively high process requirements and requires shaping, and the two pins must be on the same plane. If the processing is not in place, it will be wasted. Therefore, generally 2020-08-25 08:48:12 Beijing plug-in inductors/inductor customization/magnetic ring inductors may use magnetic ring inductors. Due to the design of the board, the plug-in magnetic ring inductor cannot be used on the customer’s board, so a flat-mounted one is used. The flat-mounted inductor has relatively high process requirements and requires shaping, and the two pins must be on the same plane. If the processing is not in place, it will be wasted. So 2020-07-27 0Rwandans Sugardaddy9:08:08 Single-cycle control scheme based on bridgeless APFC circuit. In the early days, power factor correction was implemented by adding filter inductors and capacitors after the rectifier, and the power factor was generally only about 0.6. In the 1990s, active power factor correction (APFC) was born, which directly enters a DC/DC between the rectifier and the load. Switching converter, its basic principles 2018-09-28 16:29:47 How to reduce electromagnetic interference of iron-silicon-aluminum magnetic ring inductance The composition of the iron-silicon-aluminum magnetic powder core includes 85% iron (Fe), 9% silicon (Si) , and 6% aluminum alloy powder (Al), which has the advantages of high energy storage, high saturation magnetic flux density and stable performance at low temperatures. It is very suitable for power factor correction circuits. It is a kind of low loss and relatively high saturation 2017-07-10 14:48RW Escorts: 24How to judge the quality of magnetic ring inductance? The electromagnetic waves radiated and leaked from electronic equipment seriously interfere with the normal operation of other electronic equipment, causing equipment performance disorders and transmission errors. At this time, to reduce the electromagnetic interference (EMI) of electronic equipment, we will think of magnetic toroidal inductors, and magnetic toroidal inductors do not disappoint us. Excellent anti-interference effect, can be very good2017-07-12 10:20:10How to understand filter capacitors, common mode inductors, and magnetic beads? What requirements do common mode inductors need to meet when manufacturing them? From design, how to understand the principles of EMC filter capacitors, common mode inductors, and magnetic beads? 2021-03-0608:05:40 How to configure the magnetic core selection plan? Only a small part of the magnetic materials are used. It mainly introduces the component selection of metal soft magnetic powder cores. If you are not familiar with the performance of magnetic powder cores, this software will allow you to easily solve the selection problem. This auxiliary document mainly focuses on the selection of filter inductors, energy storage inductors, PFC inductors, and reactors. Contact phone number: ***QQ: 3766956652010-12-23 15:16:17 Can I-shaped inductors and ordinary magnetic ring inductors be replaced with each other? Can an ordinary magnetic toroid inductor with the same inductance value replace the I-shaped inductor? 2015-06-24 10:58:29What are the soft magnetic materials required in differential mode inductors? Any low-pass filter composed of differential mode filter inductors and differential mode capacitors. The working principle of the differential mode filter inductor: When the low-frequency peak current or DC current flows through the power line under the filter inductor coil, the magnetic core is not saturated, while maintaining sufficient incremental magnetic permeability and inductance to ensure that it has high-frequency interference Noise 2016-01-15 15:01:55 What type of magnetic switch does the movable version of the Bluetooth headset with magnetic suction performance use? The Bluetooth headset with magnetic suction performance relies on the opening and closing of the magnet to control the switch. What type of magnetic switch does it use? Control switch 2017-04-12 18:17:00 Xinchenyang Capacitance and Inductance: The difference between inductance and SMD magnetic beads `1. A coil with more than one turn is usually called an inductor coil, and a coil with less than one turn (the wire runs through the magnetic ring ) coils are often called magnetic beads; 2. Inductors are energy storage components, while chip magnetic beads are energy conversion (consumption) devices; 3. Inductors are mostly used in power supply filter circuits, and magnetic beads are mostly used in electronic signal circuits. EMC2015-04-03 17:48:12 What is the difference between ohm resistor/magnetic bead/inductor? What is ohm resistor? What are magnetic beads? What is an inductor? What is the difference between magnetic beads and inductors? 2021-03-16 07:03:04 Please tell me, inductors RW Escorts, the difference between magnetic flux and magnetic flux The entanglement between the two is 90 degrees ahead (physical level, medium polarization delay?). I actually think this question is a mathematical question, just like why the differential of sine is cosine. Anyway, I won’t take advantage of this. But many are unfamiliar with inductors, which involves electromagnetic knowledge, such as magnetic flux, flux linkage, and magnetic induction intensity. 2017-05-06 20:33:09 Zhejiang provides high-current iron-silicon-aluminum magnetic rings, customized ones Magnetic ring inductor stores use three magnetic rings in series and wind them in parallel with multiple strands of wire to meet customer requirements. Most inductor shops on the market will use two magnetic rings RW Escorts for winding, but few shops will use three magnetic rings. , three magnetic rings are more difficult. It is easier to wind enameled wire with two magnetic rings than with three magnetic rings; three magnetic rings will show faults, and the centerMagnetic 2020-04-24 11:01:24 Introduction to how to select chip inductors and magnetic beads: A large number of rational components and EMI filter components are used in PCB circuits of electronic equipment. These components include chip inductors and chip beads. The following describes the characteristics of these two devices and analyzes their general and special applications. Advantages of surface mount components 2019-05-22 09:26:15 Magnetic patch inductor for rearview mirror module circuit – Suzhou NR inductor Q is a charging IC driver, and the chip used is BQ25601. We can pass The picture clearly shows that an NR magnetic chip inductor is used in the circuit, with 100 printed on it. Through the printing of this inductor, we can clearly understand the inductance of this magnetic chip inductor. 2020-07-20 13:17:53 Detailed explanation of the characteristic parameters of inductors in electronic components: inductance, inductance material 3.1 Commonly used units for inductance include milligrams (mH) and microdigits (uH). 1mH=1000uH. 3.2 The materials of the inductor mainly include manganese-zinc ferrite, iron-silicon-aluminum, and magnetic powder core. The magnetic permeability of each inductor material is different… 2021-12-30 06:15:49 When making a homemade magnetic ring inductor, How should the circuit for measuring inductance be connected? When making a homemade magnetic ring inductor, how should the circuit for measuring inductance be connected? . 2012-08-02 15:59:27 Solving the problem of core loss in coupled inductors Core loss in inductors can adversely affect system performance. However, guessing dead center losses is a complex task, especially in complex constructions such as coupled inductors. This article examines core losses and the consequences that should be considered. This article will also discuss how to solve the core loss in coupled inductor design 2019-07-30 15:24:17 What is the difference between magnetic bead inductors and ordinary inductors? What is the difference between magnetic bead inductors and ordinary inductors? 2019-04-22 03:42:01 What is the difference between magnetic beads and inductors? What is the difference between magnetic beads and inductors? 2023-10-18 06:53:50 Why is the extra current of ferrite inductor smaller than that of magnetic beads? `Excuse me, why is the extra current of ferrite inductor smaller than that of magnetic beads? `2011-10-16 19:37:20How to choose the inductor core? This post was last edited by One Ear on 2018-6-20 09:16 When making a switching power supply, I am very confused about the selection of inductors. Do you have any good suggestions for the selection of inductor cores? 2018-06 -19 21:54:46 What are the characteristics of Chongqing Inductor Supply/Gujing GNR SMD Magnetic Inductor? –Rwanda Sugar Daddy-Gujing Electronics SMD magnetic power inductor has the following characteristics: 1. Small size, saving space. 2 Use magnetic glue to apply the coil and cut itReduces the inductor buzzing sound. 3 The metallized electrode is directly on the ferrite core, which has strong resistance to drop impact and is durable; 4 Under the same size, the rated current exceeds that of traditional power inductors 2020-06-17 09:03:46 Chongqing Inductor Supply/Fenghua The inductor replacement-Gujing Electronics case is just a reference. There are two key points in this case. One: Inductor magnetic powder and common mode inductor stores. Inductor stores need to assist customers in choosing magnetic powder. Gujing Electronics has the ability to help customers solve this problem. Other common mode inductor stores do not have such capabilities. Second: Dealing with EMC2020-05-21 14:37:23 The difference between manganese-zinc and nickel-zinc ferrite magnetic ring inductors. Ferrite magnetic ring inductors are divided into manganese-zinc ferrite magnetic rings and nickel-zinc ferrite. Magnetic rings, depending on the materials used, will produce different calcined materials. Nickel-zinc ferrite magnetic rings are mainly made of iron, nickel, and zinc oxides or salts and are manufactured using electronic ceramic technology. Manganese-zinc ferrite magnetic ring This is made of iron, manganese and zinc 2017-07-17 17:26:32 The difference between magnetic beads and inductors. Components and inductor magnetic beads are in the same track, the same book and the same text, and the same line is published in 2022- 08-03 12:33:14APFC inductor adopts magnetic powder core The design magnetic powder core has higher saturation magnetic flux density and better DC bias magnetic static linearity. When used to make APFC inductors, only by appropriately selecting the core size and the number of coil turns can the effect of reducing core loss be achieved. 2009-12-04 13:37:4342 Electronic ballast circuit with APFC Electronic ballast with APFC Current flow circuit 2009-12-20 12:15:59140 magnetic powder dynamometer The magnetic powder dynamometer is made by It is composed of stator, solid rotor, excitation coil, magnetic powder medium, bracket, base plate, etc. When the internal coil of the magnetic powder dynamometer passes current, a magnetic field is generated, causing the external magnetic powder to press the magnetic field.The lines of force form a magnetic chain, and the pulling force generated by the magnetic powder chain becomes a resistance that prevents the rotor from rotating. This force is the load torque. Change 2023-10-28 13:26:08 The difference between magnetic beads and inductors Electronic learning of inductor magnetic beads published on 2022-12-09 18:14:13Differences between inductors, magnetic beads, and zero-ohm resistance. Electronic learning on inductors and magnetic beads published on 2023-02-08 11:46:43#Meet energy storage inductor needs#High current inductor application technology Dajia’s self-developed metal magnetic powder core data design energy storage inductor Kodajia Inductor was released on 2023-07-06 11:57:50

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