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. Click here for a summary of our newest planar transformers and a detailed description for determining losses and overall efficiencies. Leakage inductance measured between pins 2 and 4 at 100 khz, 0. Winding resistance is a major factor in transformer and inductor. Planar transformers are high frequency transformers used in isolated switchmode power supplies operating at high frequency. As opposed to conventional wirewoundonabobbin transformers, planar. When designing planar transformer pc windings, designers use the same technology used by the printed, circuit board designers, and that is the current rating for a given voltage drop and temperature rise. We use cookies to provide the best possible user experience for those who visit our website. In this paper, the most important factors for planar transformer pt design including winding loss, core loss, leakage inductance and stray capacitance have been. Dc converter and your willing to reach the best possible efficiency of your application, than its most common to use a planar transformer instead of an equivalent wire wound transformer design. A sample transformer is built to be tested in circuit before a production run is started. New design rule for high frequency planar transformer. The sensor has a broad frequency bandwidth from dc up to 30 mhz, a high current rating. Ferroxcube 3 planar transformers can be constructed as stand alone components, with a stacked layer design or a small.
Planar transformers and inductors design guide add to linkedin. Evaluating planar transformers for dcdc converter designs. Standard transformer typical planar transformer copper area window area, wa ku 0. This performance is achieved when copper losses and core losses are about equal. Our worldleading design engineering team have developed custom planar transformers from 35w to 50kw in a single transformer component and inductors at 350a, as well as fully developing custom power converters utilising planar magnetics technology.
Thermal management of planar magnetics power electronics. Ferroxcube 2 exploded view of a planar transformer. We are the global market leader in the development of planar transformer technology, design and manufacture. 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. Design validations can be achieved by finite element.
Using planar transformers dcdc converter designs digikey. A highly efficient planar integrated magnetic pim design approach for primaryparallel isolated boost converters is presented. Almukhtar abstract in this work a step by step planar transformer design proccdare for flybock switchmode dcdc converter application is presented. A multilayer planar transformer the geometry of the analysed multilayer planar transformer with fundamental dimensions is presented in figure 1. The transformer was analyzed without the core and with the core. Thermal perspective the optimal design for transformers is normally set to be the balance of core and winding losses fig. Transformer design constraints there will be five constraints on transformer design that will result in the formation of a transformer core k factor, k gfe. The first step of new design rule for high frequency planar transformer with helical winding structure is proposed in the paper. From simulation work, it is found that e25066 material manufactured by avx could be the most suitable core for high frequency transformer design.
Main planar transformer board the main transformer board is comprised of 6 4oz layers and 2 2oz layers in an 8 layer pcb. When core and copper losses differ markedly, efficiency suffers badly, falling to 95% to. Pdf highperformance planar isolated current sensor for. Because of the limited available winding space it is recommended to use the maximum allowed flux densities in planar magnetics. Design guide planar transformers inductors design guide. Planar transformer designers handle the current density in a different way. He has also added several new subjects such as rotary transformer design, planar transformer design, and planar construction. Designing with planar ferrite cores elna magnetics.
The electrical efficiency of a properly dimensioned planar transformer at fullload is approximately 98% to 99%. Transformer and inductor design handbook 4th edition. Additionally, the main manufactured elements a coil made of pcb winding and ferrite magnetic core are collected. Designing a planar transformer and using the pc winding technique, reduces the window. Expanded and revised to address recent industry developments, the fourth edition of this classic reference is reorganized and improved, again serving. The hybrid planar transformer series is available in surfacemount and throughhole configurations. Planar magnetics design for lowvoltage dcdc converters. Standexmeder manufactures planar transformers for these demanding applications and. This is achieved by integrating the transformer directly into the pcb.
The author covers magnetic design theory with all of the relevant formulas along with complete information on magnetic materials and core characteristics. With the assumption that half of the total transformer. Furthermore, for both transformer and inductors the required area product ap is proportional to the power flowing through the magnetic device. Drawing out the tracks and checking tracespace clearance manually is a pain not to mention unreliable. Basic constraints core loss typical value of for ferrite materials.
Which is the best book to learn transformer designing. Transformer design integrated engineering software. Topologies include half bridge, forward wactive rest, flyback. The design of a multilayer planar transformer for a dcdc. In addition, he provides realworld, stepbystep design examples. Calculating performance of planar magnetics 2 the transformer consisted of four windings having eight layers and 38 turns total. This article presents and evaluates different designs of transformer windings for resonant switch mode topologies operating higher than 500khz, when interleaving becomes of limited use. Expanded and revised to address recent industry developments, the fourth edition of this classic reference is reorganized and improved. The window utilization, ku, comparison of the two different winding techniques is shown in figure 2012. Planar transformer design design and analysis of mechanisms. Design, modeling, and analysis of a compact planar. High efficiency low losses, ultra compact, lowprofile. Planar transformers catalog ghser14 20w series page 2 ghsrm06 50w series page 3 ghsei18 50w series page 4 ghsei18 100w series page 5. The capabilities and limitations of this core will be shown in transformer designs operat ing at 500 khz transformer frequency.
Topic 4 designing planar magnetics texas instruments. The 2oz cu plating on the outer layers of the main transformer board allows for placement of the surface mount components that make up the remainder of the dc dc converter circuitry. Planar transformers are devices used to exact standards with precise electrical characteristics such as capacitance, output, and aspect ratio. The use of planar litz wires as presented in 5 seems expensive for a competitive design. This 15 page application note presents a fast and easy method to design planar transformers based on the ferroxcube range of planar e cores. Optimal design and tradeoffs analysis for planar transformer in. It is a very good book to take help for designing problem of machines. We will use the single factor k gfe to guide the design process. Planar transformers can be used in forward, pushpull, and full bridge half bridge topologies. Wire effective resistivity cm total rms winding current, ref to pri itot a desired turns ratios n2n1, n3n1, etc. A compact planar transformer of a new design was analyzed in this paper. Does anyone know of a decent repeatable way of making planar transformersplanar inductors in altium. Inductance measured on an agilenthp 4284 between pins 2 and 4 at 200 khz, 0. The devices unique design can be optimized for customerspecific switching frequencies, input and output voltages, and current levels.
The mclyman transformer and inductor design kandbook reference 1 is a good source for this information. A planar current sensor, comprised of a magnetic current transformer and a halleffect element, is presented. Using ferritic core, the inductance was increased for 22%. 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. Design guide planar transformers inductors design guide planar transformers inductors bus bar termination customize beyond these examples. Standard part numbers are available of the shelf, and customized quickturn prototypes are available in a. The separation of the conductors of the primary winding and the secondary winding is a critical factor to determine the coupling of the transformer. 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. High frequency winding design for planar switch mode. A planar approach transformer design design of transformer indrajit dasgupta design of transformer by indrajit dasgupta pdf transformer engineering. Planar magnetics transformers and inductors for power. This document describes all the parts in the kit and provides information that covers assembling a prototype planar transformer or inductor.
However, they dont perform as well as conventional transformers when used in a flyback topology, and since they are relatively uncommon, finding one that meets your. Several books are available in the market for transformer design. Applying the basic principles of magnetic field behavior discussed in earlier seminars to planar magnetic structures enables us to optimize the design and predict. I took reference from the book a course in electrical machine design by a. Design, modeling, and analysis of a compact planar transformer. By using this website you agree to the placement of cookies. Pulse electronics optimized planar transformer er25. Analysis and design of fully integrated planar magnetics for. These unique approaches are based on the use of core designs with multiple winding areas and core sections which provide common flux paths for transformer. Our planar transformer design capability combines excellent engineering with delivering a solution that not only saves you space, time, and costs, but suits your needs uniquely and specifically. Transforming the future of power electronics planar. Design, modeling and simulation of planar waveguide time domain optical fourier transformer author.
This relation can be used to estimate the temperature rise of the transformer as a function of flux density in the core. The design and development of a novel flyback planar. Strategies for optimizing planar design are presented, and illustrated with design examples. But we must realize that this is a guide in the first step of an iterative process that may require us to change our. When it comes to standex electronics custom transformers custom is standard. Planar magnetic devices offer several advantages over their conventional counterparts. Designing a planar transformer and using the pc winding technique, reduces the window utilization factor even further. Pdf this paper presents a new design of a planar transformer. Layer design 14 design of planar power transformers. Planar transformer catalog 301 east arrow highway suite 108 san dimas, ca 917733364 telephone.
Planar inductors are low profile and have exceptional current handing. If the result yields an unacceptable temperature, a. Xun li professor, department of electrical and computer engineering number of pages. The design and development of a novel flyback planar transformer for high frequency switch mode dcdc converter applications part 1 k. The pcb layout of the forward transformer is included.
Some designs of ltcc ferrite transformers were reported. Complete designs for a forward and a flyback transformer are given. With its practical approach to design, transformer and inductor design handbook, fourth edition distinguishes itself from other books by presenting information and guidance that is shaped primarily by the users needs and point of view. The benefits of planar magnetics in of power conversion. Benyaakov, the benefits of planar magnetics in hf power conversion 3 that is, an increase in cross section area allows a proportional decrease in the number of turns. Magnetics designer produces a complete transformer or inductor design based upon electrical specifications, including a winding sheet report and a spicecompatible model with parasitics. Introduction to planar magnetic pcb design terratel. This paper discusses the magnetic fields within the planar structure and their effects on the distribution of high frequency currents in the windings. Planar designs offer advantages that include low leakage inductance. The design development a novel flyback planar transformer.
In general, there is not a huge difference between implementing a planar transformer versus a comparable conventional transformer in a dcdc converter design. The transformer is one of the fi rst critical components in the. Planar transformer design in gan based llc resonant. We changed the voltage ratio by using different seriesparallel connections. Harper, handbook of electronic packaging, mcgrawhill book company, pp.
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