Tutorial - Inductor Databases in Thermal Module...PSIM Tutorial– Inductor Databases in the Thermal Module - 18 - Powersim Inc. - Length: 1.2 - Width: 2 - Isolation Thickness: 0.05

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PSIM Tutorial Inductor Databases in the Thermal Module

January 2015

PSIM Tutorial– Inductor Databases in the Thermal Module


A typical inductor, as shown below, consists of three main parts: core, bobbin (also called coil former), and winding. To construct an inductor in the Thermal Module, three databases are used: core material database, core database, and winding database.

This tutorial describes how these databases are defined.

Core Material Database:

The core material database requires the following information:

- Manufacturer: Name of the manufacturer (e.g. Ferroxcube) - Type: Material type (e.g. Ferrite) - Material: Material name (e.g. 3F3, 3C90) - mur: Relative permeability µr of the material at 25oC - Ploss vs. Bpk: Graph of power loss Ploss vs. peak flux density Bpk - Ploss vs. Tc: Graph of power loss Ploss vs. core temperature Tc

All the information can be obtained from the manufacturer datasheet.

For example, for Ferroxcube material 3C90, the value µr can be obtained from Page 84 of the Ferroxcube datasheet, and the graphs Ploss vs. Bpk and Ploss vs. Tc can be obtained from Page 85 of the datasheet, as shown below (highlighted in the red boxes).

µr

Core

Bobbin or Coil Former



To enter this material into the core material database, in PSIM, launch the Device Database Editor from the Utilities menu. In the Device Database Editor, select Device >> Edit Core Material Database. On the dialog, click on New, and enter the following:

- Manufacturer: Ferroxcube - Type: Ferrite - Material: 3C90 - mur: 2300

Click on Add to list to add the new material to the list on the left. Then click on the Edit button next to Ploss vs. Bpk to capture all the four curves of Ploss vs. Bpk. For the graph Ploss vs. Tc, capture the middle curve that corresponds to frequency of 200kHz and Bpk of 100mT. Use the same procedure as described in Section 4.10.6 of the PSIM User Manual to capture the curves. The database editor dialog will appear as follows:



Core Database:

The core database defines the core and bobbin type and size. It requires the following information:

- Manufacturer: Name of the core and bobbin manufacturer (e.g. Ferroxcube) - Type: Core type (e.g. EE, RM) - Model: Core model (e.g. EE42/21/15, RM8) - Column Type: Shape of the center column. It can be: 0 for round, or 1 for rectangular. - Shape Type: Shape of the core. It can be: 0 for Type A, 1 for Type B; and 2 for Other

Type. - Material: Supported materials by this core (i.e. 3F3, 3C90, etc.) - Ae: Effective area, in mm2 - Ve: Effective volume, in mm3 - Le: Effective length, in mm - N_col: Number of column of the core - Diameter1: Bobbin diameter of a round core, in mm - Diameter2: Bobbin diameter of a round core, in mm - Diameter3: Bobbin diameter of a round core, in mm - Height1: Bobbin height H1, in mm - Height2: Bobbin height H2, in mm - Width1: Bobbin width of a rectangular core, in mm - Width2: Bobbin width of a rectangular core, in mm - Width3: Bobbin width of a rectangular core, in mm - Depth1: Bobbin depth of a rectangular core, in mm - Depth2: Bobbin depth of a rectangular core, in mm - Depth3: Bobbin depth of a rectangular core, in mm - CoH1: Core Height 1, in mm - CoH2: Core Height 2, in mm - CoW1: Core Width 1 of a Type A core, in mm - CoW2: Core Width 2 of a Type A core, in mm - CoD: Core depth of a Type A core, in mm - CoDi1: Core diameter of a Type B core, in mm - CoE1: Core space of a Type B core, in mm - Clip Vertical: Percentage of the clip area in the vertical direction - Clip Horizontal: Percentage of the clip area in the horizontal direction

Note that, depending on the type of the cores, not all the parameters are required.

The effective area, volume, and length are read directly from the datasheet. For Ferroxcube’s E core E42/21/15, for example, the values are marked in the red box below:



Bobbin Dimension:

In general, the column of a core can be either round or rectangular. The core bobbins are shown below. The required parameters are heights, widths, and depths for rectangular cores, and heights and diameters for round cores.

The required dimensions of the bobbin are labelled on the diagram.

Rectangular leg cores include: E and EFD. Round leg cores include: EC, EP, EQ, P, and RM.

Core Dimension:

The shape of a core can be Type A, B, or Other type. The required parameters of Type A and B are marked in the diagram below.

Depth1

Depth2 Depth3

Width1

Width2

Width3Height1

Height2

Rectangular Leg Core

Height1

Height2

Diameter1

Diameter2

Diameter3

Round Leg Core

CoH1 CoH2

CoH1 CoH2

CoW1

CoW2

CoD

CoE1 CoDi1

Type A Type B



Below are examples of different core bobbins and their dimensions for the core database:

E Core 1:

E Core 2:

E Core 3:

E42/21/15: Height1 = 26.2 Height2 = 28 Width1 = 15.7 Width2 = 17.9 Width3 = 34 Depth1 = 12.6 Depth2 = 14.6 Depth3 = 29

E5.3/2.7/2: Height1 = 2.6 Height2 = 3.7 Width1 = 2.15 Width2 = 2.9 Width3 = 4.7 Depth1 = 1.5 Depth2 = 2.3 Depth3 = 3.6

E13/7/4: Height1 = 7.1 Height2 = 8.5 Width1 = 3.9 Width2 = 5.2 Width3 = 8.7 Depth1 = 3.9 Depth2 = 5.2 Depth3 = 9.6



E Core 4:

EFD Core:

EC Core:

EP Core:

E20/10/5: Height1 = 10.8 Height2 = 12.6 Width1 = 5.3 Width2 = 7 Width3 = 12.7 Depth1 = 5.3 Depth2 = 7 Depth3 = 12.7

EC35: Height1 = 21.5 Height2 = 30.5 Diameter1 = 9.85 Diameter2 = 12.2 Diameter3 = 21.9

EFD15/8/5: Height1 = 9.15 Height2 = 10.4 Width1 = 5.5 Width2 = 6.65 Width3 = 10.55 Depth1 = 2.6 Depth2 = 3.7 Depth3 = 7.5

EP7: Height1 = 3.65 Height2 = 4.85 Diameter1 = 3.5 Diameter2 = 4.4 Diameter3 = 7

Height1 = 4.85-0.6*2 = 3.65



EQ Core:

RM Core 1:

RM Core 2:

P Core 1:

RM5/I: Height1 = 4.7 Height2 = 6.1 Diameter1 = 5 Diameter2 = 5.9 Diameter3 = 10.1

RM6S: Height1 = 6.26 Height2 = 7.85 Diameter1 = 6.5 Diameter2 = 7.45 Diameter3 = 12.3

EQ30: Height1 = 8.4 Height2 = 10 Diameter1 = 11.3 Diameter2 = 12.9 Diameter3 = 25.6

CP-P9/5-1S: Height1 = 2.7 Height2 = 3.5 Diameter1 = 4 Diameter2 = 4.78 Diameter3 = 7.35



P Core 2:

PT Core:

PQ Core:

CP-P18/11: Height1 = 6 Height2 = 7 Diameter1 = 7.7 Diameter2 = 8.7 Diameter3 = 14.8

Height1 = 7-0.5*2 = 6

PT14/8: Height1 = 4.06 Height2 = 5.51 Diameter1 = 6.15 Diameter2 = 7.16 Diameter3 = 11.53

PQ20/16: Height1 = 7.82 Height2 = 9.8 Diameter1 = 9 Diameter2 = 10.8 Diameter3 = 17.35



Below are examples of different cores and their dimensions for the core database:

E Core:

EFD Core:

EC Core:

E42/21/15: CoH1 = 14.8*2 = 29.6 CoH2 = 21*2 = 42 CoW1 = 29.5 CoW2 = 43 CoD = 15.2

EFD10/5/3: CoH1 = 3.75*2 = 7.5 CoH2 = 5.2*2 = 10.4 CoW1 = 7.65 CoW2 = 10.5 CoD = 2.7

EC35: CoH1 = 12.3*2 = 24.6 CoH2 = 17.3*2 = 34.6 CoW1 = 22.75 CoW2 = 35.3 CoD = 9.5



EP Core:

EQ Core:

RM Core:

EP7: CoH2 = 7.5 CoW2 = 9.4 CoD = 6.5

EQ13: CoH1 = 1.75*2 = 3.5 CoH2 = 2.85*2 = 5.7 CoW1 = 9.05 CoW2 = 12.8 CoD = 8.7

RM4: CoH1 = 7 CoH2 = 10.4 CoW1 = 5.8 CoW2 = 11 CoD = 4.6



P Core (Type B):

PT Core (Type B):

PQ Core:

P9/5: CoH1 = 3.6 CoH2 = 5.4 CoDi1 = 9.3 CoE1 = 2

PT14/8: CoH1 = 5.86 CoH2 = 8.3 CoDi1 = 14.05 CoE1 = 3.3

PQ20/16: CoH1 = 10.3 CoH2 = 16.2 CoW1 = 12 CoW2 = 21.3 CoD = 14



Winding Database:

The winding database defines the wire type and dimensions for the winding. It requires the following information:

- Type: Type of wire. It can be Round, Strip (rectangular), and Litz wire. - Model: Model name of the wire (e.g. AWG18) - Inner Diameter: Inner diameter of the wire (for the Round wire) or wire bundle (for the

Litz wire), in mm - Outer Diameter (1 layer): Outer diameter of the round wire with 1 layer insulation, or

outer diameter of the Litz wire bundle with 1 silk layer isolation, in mm - Outer Diameter (2 layer2): Outer diameter of the round wire with 2 layer insulation, or

outer diameter of the Litz wire bundle with 2 silk layer isolation, in mm - Length: Length of the Strip wire - Width: Width of the Strip wire - Insulation Thickness: Insulation thickness of the Strip wire - Diameter Single Wire: Outer diameter of a single Litz wire - Wire Number: Number of wires in one Litz wire bundle - Wire Bundles: Number of wire bundle

The picture below shows these three types of wires:

Their dimensions are defined as below:

The following are examples of the winding definition.

For an AWG18 round wire:

- Type: Round - Model: AWG18 - Inner Diameter: 1.024 - Outer Diameter (1 layer): 1.0726 - Outer Diameter (2 layers): 1.1243

For a strip wire with a length of 1.2mm, width of 2mm, and isolation thickness of 0.05mm:

- Type: Strip - Model: ST_1.2_2

Round Strip Litz

Inner Diameter

Outer Diameter

Width

Length Isolation Thickness

Outer Diameter

Inner Diameter

Wire Bundle

Silk Layer



- Length: 1.2 - Width: 2 - Isolation Thickness: 0.05

For a Litz wire with: single wire diameter 0.04mm, 12 wires per bundle, 1 bundle, wire bundle inner diameter 0.208mm, wire bundle outer diameter 0.243 (1 layer) and 0.278mm (2 layers):

- Type: Litz - Model: 1x12x0.04 - Inner Diameter: 0.208 - Outer Diameter (1 layer): 0.243 - Outer Diameter (2 layers): 0.278 - Diameter Single Wire: 0.04 - Wire Number: 12 - Wire Bundle: 1

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Tutorial - Inductor Databases in Thermal Module...PSIM Tutorial– Inductor Databases in the Thermal Module - 18 - Powersim Inc. - Length: 1.2 - Width: 2 - Isolation Thickness: 0.05