Analytical Winding Power Loss Calculation in Gapped Magnetic Components

The analytical calculation of winding loss in gapped magnetic components is complex, and numerical analysis tools, such as finite elements analysis (FEA) tools, are commonly needed to characterize the windings. As FEA tools are used, the required design time of these types of components increases greatly when many simulations are needed to select the appropriate component for a given application, and simple analytical models become necessary to reduce the design time. In this paper, some analytical approaches for winding loss calculation in gapped magnetic components are reviewed and a general two-dimensional equivalent method, which aims to consider the frequency effects in conductors in a simplified manner, is proposed afterward. Due to its simplicity, it can be integrated into design and optimization tools in order to evaluate the influence of the air gap over the winding loss even at the early stages of the design process. The presented model shows good agreement with FEA simulations and measurements.

Basic Power Inductor Design

<p>A basic procedure for designing a power inductor is presented. Many papers and textbook chapters offer more sophisticated methods, but it is harder to find a clear outline of a basic design process. Studying and practicing a basic design process is useful for beginners to understand the fundamental tradeoffs in design and to build intuition. For more advanced work, the basic design process is useful as it avoids relying on assumptions that might not be valid with, for example, high-frequency loss effects that are ignored in the development of some more sophisticated methods, or that constrain other methods to narrow, specific cases.</p> <p>Two options are outlined: starting with a saturation constraint, and then checking the core/winding loss balance; or, starting by optimizing the core/winding loss balance, and then checking the saturation constraint.</p>

Basic Power Inductor Design

<p>A basic procedure for designing a power inductor is presented. Many papers and textbook chapters offer more sophisticated methods, but it is harder to find a clear outline of a basic design process. Studying and practicing a basic design process is useful for beginners to understand the fundamental tradeoffs in design and to build intuition. For more advanced work, the basic design process is useful as it avoids relying on assumptions that might not be valid with, for example, high-frequency loss effects that are ignored in the development of some more sophisticated methods, or that constrain other methods to narrow, specific cases.</p> <p>Two options are outlined: starting with a saturation constraint, and then checking the core/winding loss balance; or, starting by optimizing the core/winding loss balance, and then checking the saturation constraint.</p>