Transformer and Inductor Design Handbook Fourth Edition.pdf

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Transformer and Inductor Design Handbook Fourth Edition.pdf
CRC Press Taylor Francis Group 6000 Broken Sound Parkway nw, Suite 300 Boca raton Fl 33487-2742 C 2011 by Taylor and Francis Group, LLC CRC Press is an imprint of Taylor Francis Group, an Informa business No claim to original U.s. Government works Printed in the United States of America on acid-free paper 10987654321 International Standard Book Number-13: 978-1-4398-3688-0(Ebook-PDE This book contains information obtained from authentic and highly regarded sources. Reasonable efforts have been made to publish reliable data and information, but the author and publisher cannot assume responsibility for the validity of all materials or the consequences of their use. The authors and publishers have attempted to trace the copyright holders of all material reproduced in this publication and apologize to copyright holders if permission to publish in this form has not been obtained. If any copyright material has not been acknowledged please write and let us know so we may rectify in any future reprint Except as permitted under U.S. Copyright Law, no part of this book may be reprinted, reproduced, transmitted, or utilized in any form by any electronic mechanical, or other means, now known or hereafter invented, including photocopying, microfilming, and recording, or in any information storage on retrieval system, without written permission from the publishers Forpermissiontophotocopyorusematerialelectronicallyfromthisworkpleaseaccesswww.copyright.com(http:/www.copyright.com/)orcontact he Copyright Clearance Center, Inc(CCC), 222 Rosewood Drive, Danvers, MA 01923, 978-750-8400. CCC is a not-for-profit organization that provides licenses and registration for a variety of users. For organizations that have been granted a photocopy license by the CCC, a separate system of payment Trademark Notice: Product or corporate names may be trademarks or registered trademarks, and are used only for identification and explanation ithout intent to infringe Visit the taylor francis Web site at http://www.taylorandfrancis.com and the crc press web site at http://www.crcpress.com c 201 1 by taylor and francis group llC To My Wife, bonnie c 201 1 by taylor and francis group llC Contents Foreword ix Preface xi Acknowledgements xiii About the author xv Symbols xvii Chapter 1 上 undamental of magnetics.… l-1 Chapter 2 Magnetic materials and Their Characteristics apter Magnetic Cores…… Chapter 4 window utilization, Magnet wire, and insulation Chapter 5 Transformer design trade-offs 5-1 Chapter 6 Transformer-Inductor Efficiency, Regulation, and Temperature Rise Chapter 7 Power Transformer Design……… 7-1 Chapter 8 DC Inductor Design, Using Gapped Cores Chapter g DC Inductor Design, Using Powder Cores Chapter 1o AC Inductor Design. .......10-1 Chapter 11 Constant Voltage Transformer(CVT) 11-1 Chapter 12 Three-Phase Transformer Design .12-1 c 201 1 by taylor and francis group llC v Contents Chapter 13 Flyback Converters, Transformer Design :: 13-1 Chapter 14 Forward Converter, Transformer Design, and Output Inductor Design 14-1 Chapter 15 Input Filter Design… 15-1 Chapter 16 Current Transformer design 16-1 Chapter 17 Winding Capacitance and Leakage Inductance .17-1 Chapter 18 Quiet Converter Design……… ..……18-1 Chapter 1y Rotary Transformer Design 19-1 Chapter 20 Planar transformers and Inductors 20-1 Chapter 21 Derivations for the Design equations 21-1 Chapter 22 Autotransformer design ……2-1 Chapter 23 Common-Mode Inductor design .23-1 Chapter 24 Series saturable reactor design 24-1 Chapter 25 Self-Saturating, Magnetic Amplifiers 25-1 Chapter 26 Designing Inductors for a Given Resistance. 26-1 c 201 1 by taylor and francis group llC Foreword Colonel Mclyman is a well-known author, lecturer and magnetic circuit designer. His previous books on transformer and inductor design, magnetic core characteristics and design methods for converter circuits have been widely used by magnetics circuit designers In his 4th edition, Colonel McLy man has combined and updaled the information found in his previous books. He has also added five new subjects such as autotransformer design, common-mode inductor design, series saturable reactor design, self-saturating magnetic amplifier and designing inductors for a given resistance. The author covers magnetic design theory with all of the relevant formulas. He has complete information on all of the magnetic materials and core characteristics along with the real world, step-by-step design examples This book is a must for engineers doing magnetic design. Whether you are working on high"" state of the art design or high volume, or low cost production, this book will help you. Thanks Colonel for a well-done useful bo Robert. Noah Application Engineering Manager(Retired) Magnetics, Division of Spang and Company Pittsburgh, Per nn.sylvania c 201 1 by taylor and francis group llC Preface I have had many requests to update my book Transformer and Inductor Design Handbook, because of the way power electronics has changed in the past few years. I have been requested to add and expand on the present Chapters. There are now twenty-six Chapters. The new Chapters are autotransformer design, common-mode inductor design, series saturable reactor design, self-saturating magnetic amplifier and designing inductors for a given resistance, all with step-by-step design examples This book offers a practical approach with design examples for design engineers and system engineers in the electronics industry, as well as the aerospace industry. while there are other books available on electronic transformers, none of them seem to have been written with the users view point in mind. The material in this book is organized so that the design engineer, student engineer or technician, starting at the beginning of the book and continuing through the end, will gain a comprehensive know ledge of the state of the art in trans- former and inductor design. The more experienced engineers and system engineers will find this book a useful tool when designing or evaluating transformers and inductors. Transformers are to be found in virtually all electronic circuits. This book can easily be used to design light weight, high-frequency aerospace transformers or low-frequency commercial transformers. It is, therefore a design manual The conversion process in power electronics requires the use of transformers, components that frequently are the heaviest and bulkiest item in the conversion circuit Transformer components also have a significant effect on the overall performance and efficiency of the system. Accordingly, the design of such transformers has an important infuence on overall system weight, power conversion efficiency, and cost. Because of the interdepen dence and interaction of these parameters, judicious trade-offs are necessary to achieve design optimization Manufacturers have for years assigned numeric codes to their cores to indicate their power- handling ability This method assigns to each core a number called the area product, An, that is the product of its window area Wa, and core cross-section area, A. these numbers are used by core suppliers to sum marize dimensional and electrical properties in their catalogs. The product of the window area, Wa, and the core area, Ac, gives the area product, Ap, a dimension to the fourth power. I have developed a new equation for the power-handling ability of the core, the core geometry, Kg. The core geometry, K, has a dimension to the fifth power. This new equa- tion gives engineers faster and tighter control of their design. The core geometry coefficient, Ky, is a relativel new concept, and magnetic core manufacturers are now beginning to put it in their catalogs Because of their significance, the area product, An, and the core geometry, Ko, are treated extensively in this handbook. a great deal of other information is also presented for the convenience of the designer. Much of the material is in tabular form to assist the designer in making the trade-offs best suited for the particular applica tion in a minimum amount of time c 201 1 by taylor and francis group llC Preface Designers have used various approaches in arriving at suitable transformer and inductor designs. For example in many cases a rule of thumb used for dealing with current density is that a good working level is 1000 circu lar mils per ampere. This is satisfactory in many instances; however, the wire size used to meet this require ment may produce a heavier and bulkier inductor than desired or required. The information presented here will make it possible to avoid the use of this and other rules of thumb, and to develop a more economical and better design The author or the publisher assumes no responsibility for any infringement of patent or other rights of third parties that may result from the use of circuits, systems, or processes described or referred to in this handbook I wish to thank the manufacturers represented in this book for their assistance in supplying technical data Colonel wm. T McLyman c 201 1 by taylor and francis group llC Acknowledgements In gathering the material for this book, I have been fortunate in having the assistance and cooperation of several companies and many colleagues. As the author, I wish to express my gratitude to all of them. The list is too long to mention them all. however, there are some individuals and companies whose contributions have been significant Colleagues that have retired from Magnetics include robert Noah and Harry Savisky who helped so greatly with the editing of the final draft. Other contributions were given by my colleagues at Magnetics Lowell Bosley and his staff with the sending of up-to-date catalogs and sample cores. I would like to thank colleagues at Micrometals Corp . Jim Cox and Dale Nicol, and George Orenchak of Tsc International. I would like to give a special thanks to Richard (Oz) Ozenbaugh of Linear Magnetics Corp for his assistance in the detai led derivations of many of the equations and his efforts in checking all the design examples. I would also like to give special thanks to Steve Freeman of Rodon Products, Inc and Charles Barnett of Leightner Electronics, Inc for building and testing all of the magnetic components used in the design examples There are individuals i would like to thank: Dr. Vatche Vorperian of Jet Propulsion Laboratory (PL) for his help in generating and clarifying equations for the Quiet Converter; Jerry Fridenberg of Fridenberg Research Inc for modeling circuits on his SPICe program: Dr. Gene Wester of (JPL) for his inputs and Kit Sum for his assistance in the energy storage equations. I also want to thank the late robert yahiro for his help and encour agement over the years c 201 1 by taylor and francis group llC 【实例截图】
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