Analysis of Common Wrong Concepts in the Design of High Frequency Magnetic Components in Switching P

1. Introduction

The design of high frequency magnetic components in switching power supply is very important for the normal operation of the circuit and the realization of various performance indexes. In addition, the design of high-frequency magnetic components includes many detailed knowledge points, and these details are difficult to be listed clearly by one or several so-called "Design Encyclopedia". In order to optimize the design of high-frequency magnetic components, multiple design variables must be considered and adjusted repeatedly according to the application. Because of this, the design of high-frequency magnetic components has always been a headache for designers who are new to the field of power supply, and even a problem for power supply engineers with many years of work experience.

The design methods or formulas of magnetic components given in many literatures and related technical data often directly ignore the influence of some design variables, and a set of formulas are obtained after assumptions and simplification; Or the application conditions of the formula are not explained clearly, and even the information conveyed in some documents is incorrect. Many power supply designers are not aware of this, directly apply the formulas in the design manual, or take some words out of context in the design manual and respect them as "design program", without thorough analysis, thinking and experimental verification. As a result, the designed high-frequency magnetic components can not meet the requirements of applications, affecting the progress of R & D and the completion of the project on schedule.

In order to make power designers avoid making the same mistakes in the design process, we summarize some conceptual problems encountered in learning and R & D, hoping to provide you with a reference.

2. Discrimination of some wrong concepts

Here, eight common wrong concepts in the design of high frequency magnetic components of switching power supply are given in the form of subheadings, and analyzed in detail.

1) Filling the core window -- optimal design

Many power designers believe that in the design of high-frequency magnetic components, filling the core window can obtain the optimal design, but it is not. In the design of many high-frequency transformers and inductors, we can find that adding one or more layers of windings or using enamelled wires with larger wire diameter can not obtain the optimization effect, but will increase the total winding loss due to the proximity effect in the winding. Therefore, in the design of high-frequency magnetic components, even if the winding does not fully wind the iron core window, only 25% of the window area is wound, it does not matter. You don't have to try to fill the whole window area.

This wrong concept is mainly affected by the design of power frequency magnetic components. In the design of power frequency transformer, the integrity of iron core and winding is emphasized, so there is no gap between iron core and winding. Generally, the winding is designed to fill the whole window, so as to ensure its mechanical stability. However, the design of high frequency magnetic components does not have this requirement.

2) "Iron loss = copper loss" -- optimized transformer design

Many power supply designers, even in many magnetic component design reference books, list "iron loss = copper loss" as one of the standards for the optimal design of high-frequency transformer, but it is not. In the design of high-frequency transformer, the difference between iron loss and copper loss can be large, and sometimes the difference can even reach an order of magnitude, but this does not mean that the design of high-frequency transformer is not good.

This wrong concept is also affected by the design of power frequency transformer. Because of the large number of winding turns and large area of power frequency transformer, the empirical design rule of "iron loss = copper loss" is obtained from the perspective of thermal stability and thermal uniformity. However, for high-frequency transformers, this rule of thumb does not hold when very fine enamelled wires are used as windings. In the design of switching power supply high frequency transformer, there are many factors to determine the optimal design, and "iron loss = copper loss" is actually the least concerned aspect.

3) Leakage inductance = 1% magnetization inductance

When many power supply designers submit relevant technical requirements to transformer manufacturers after designing magnetic components, they often need to explain the requirements of leakage inductance. On many technical sheets, similar technical requirements such as "leakage inductance = 1% magnetization inductance" or "leakage inductance

Analysis of Common Wrong Concepts in the Design of High Frequency Magnetic Components in Switching P 1

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