3.

DESIGN OF INDUCTORS

3.1 INTRODUCTION

Even though inductors and transformers are both magnetic components, there is a
very important difference in their functioning and design aspect. In a transformer,
the core flux (or the flux density) is decided by the magnetising current. The load
current virtually has no say in deciding the core flux (the flux due to the load
current is nullified by the counter flux produced by the primary component of the
load current). Where as in an inductor, the core flux is decided only by the load
current. Thus if the load current increases, there is a possibility that the core may
saturate and inductance will come down. So the primary consideration in an
inductor is that one has to know the maximum load current and have the core
which does not saturate at this current. This can lead to a huge core size if the
current to be handled is large. The core size can be reduced considerably by
introducing an appropriate air gap in the magnetic circuit. Figure 4.1 (a) and (b)
show the effect of an air gap on the B-H characteristics of the magnetic material
illustrating clearly that with the airgap, the coil can carry considerably larger
current without saturating the core.

3.2 PRINCIPLES OF INDUCTOR DESIGN

There are several approaches to inductor design, two of which are mentioned
below:

Trial and error approach often guided by the "Hanna Curves".

Area product approach.

Here the Area Product approach is discussed as it is a sound design technique

and is also easy to follow. Figure 3.2 shows the inductor geometry using an EI
core. Using the Faraday's law one has,

d
e=N dt (3.1)

Dr.L.Umanand, CEDT, IISc, Bangalore-560012 31

 B1

H1 H2

(a) Without airgap (b) With airgap

Fig. 3.1 B-H Curves

Lg

Fig. 3.2 Inductor Geometry with E-I core


Rc

Ni mmf Rg

Fig.3.3 Model of Magnetic circuit for the inductor

32 Dr.L.Umanand, CEDT, IISc, Bangalore-560012

The equivalent magnetic circuit is shown in figure 3.3. Note that Rc and Rg are
the core and air gap reluctances. They are given by the following relationships,

lc lg
Rc = 0 r Ac
; Rs = 0 Ac
(3.2)

(assuming the area of cross sections of the core and air gap to be equal i.e.
neglecting the fringing flux.), flux in the circuit of the figure 3.3 is given by

 mmf
Rc R g  lc
Ni
lg (3.3)

0 r Ac 0A c

Using equation 3.3, equation 3.1 can be rewritten as,

  L didt
d N2 di
e=N dt lc lg dt (3.4)
;; A c
0 r Ac 0

where the inductance L is given by

N2
L= lc lg (3.5)
;; Ac
0 rA c 0

If lg, the air gap length is zero, then

2
0 r Ac N
L= lm (3.6)

which is the familiar expression of the inductance.

For a core with high permeability, the factor lc / (0rAc) can be neglected with
respect to lg / (0Ac) i.e. the reluctance of the magnetic material is much less than
that of the air gap. Thus equation 3.5 simplifies to
2
0 AcN
L= lg (3.7)

2
0 AcN
i.e. lg = L (3.8)

3.3 DESIGN OF INDUCTOR

Inductor value: The first step towards the inductor design is to find out the value
di
of L for the particular application. The Faraday's equation e = L dt is used to
find the value of L for any circuit. This equation is best suited for switched mode
applications. For circuits based on resonant principle, the L value is determined
from the resonant frequency and the Q of the circuit etc.. So depending on the
type of application and the configuration of the circuit, the value of L has to be
arrived at.

Area Product: The energy to be handled by the inductor core is given by

Dr.L.Umanand, CEDT, IISc, Bangalore-560012 33

 E = 1/2 LI2 m (3.9)

where, E is the energy in joules, L is the inductance in Henrys and Im is the peak
inductor current in amps. The window area of the core should accommodate 'N'
turns of wire cross-section area 'a'. Thus,

Kw Aw = N.a (3.10)
I
But, a = J , where I is the rms current through the inductor in amps and J is the
current density in A/mm2. So, equation 3.10 can be rewritten as
I
Kw Aw = N J (3.11)

Defining crest factor Kc as

Kc 
Im (peak )
I (rms )
, and substituting for I from equation 3.11, one obtains,

Kw KcAw J = NIm (3.12)

From the Faraday's equation, it is evident that,

e = L dt; N  NAc dB
di d
dt dt
and

LIm = NAcBm (3.13)

Substituting equation 3.13 in equation 3.9, one obtains

E = 1/2 NIm AcBm (3.14)

Substituting for Im in equation 3.14 from equation 3.12 and rearranging, the Area
Product for the core is given by,
2E
Ap = Aw Ac = Kw K c JBm (3.15)

As there is only one winding, Kw can be chosen as o.6. The core can be chosen
by comparing the area product value obtained from equation 3.15 with the cores
in Appendix-I.

No. of turns: The number of turns can be calculated from equation 3.13,
which can be rewritten as
LI m
N= Ac B m (3.16)

Gauge of wire:The cross-section area of the wire can be calculated from the
formula,

a = I/J (3.17)

34 Dr.L.Umanand, CEDT, IISc, Bangalore-560012

The gauge of the wire can be decided by comparing the calculated wire cross
section from equation 3.17 with wire gauges given in Appendix-II.

Air gap, lg: As per section 3.1, air gap, lg , is used to reduce the core size.

From the Faraday's equation, it is evident that

LI
B= NAc (3.18)

where B = Ac

from Ampere's Law, one obtains

.
mmf = NI = H.dl, which gives rise to

NI
H = l m where lm is the mean magnetic path length

NI
so, B = lm (3.19)

Equating equations 3.18 and 3.19, one obtains

 N2
lm
Ac L (3.20)

lm
Ac is the reluctance of the magnetic path which can


lc lg
be split into 0 r Ac 0 Ac
,

where,
lc is the mean magnetic path in the magnetic material, m
lg is the air gap length, m
Ac is the core section, m2
If the material is of high permeability one, then the reluctance is contributed mainly
by the air gap, so


lc lg
0 r Ac 0 Ac

so equation 3.20 can be rewritten as,

2
0N Ac
lg = L (3.21)

In calculating N, Bm is assumed, which may not be the exact Bm in the core, so

the air gap calculated may not be exact. So in many cases, value of L may have
to be trimmed by slightly adjusting the airgap.

Dr.L.Umanand, CEDT, IISc, Bangalore-560012 35

 3.4 SUMMARY OF DESIGN PROCEDURE

Determine L for the particular application.

Calculate Area Product

E = 1/2 LI2m
2E
Ap = Aw Ac = Kw K c JBm

take Bm = 0.2T for ferrite, Bm = IT for CRGO, J = 3 A/mm2

and Kw = 0.6
Choose the core from Appendix - I.

Calculate the number of turns

LI m
N= Ac B m

Determine the Gauge of the wire

a=I/J

Choose the Gauge of the wire from Appendix - II.

Cross Check

The inequality, AwKw >a.N should be satisfied, or else repeat the calculatins
for the number of turns and guage of wire after choosing the next bigger
core. Note that the value of 'a' should be the actual cross section area of
the wire used and not the calculated value.

Calculate air gap length, lg

2
0N Ac
lg = L

Example : Design an Inductor for a Buck (non isolated forward converter)

Converter Configuration as shown in figure 3.4, for the following specifications:
Output voltage, V0 5V
Output current, I0 5A
Switching Freq., fs 40 KHz
Input Voltage, Vg 12V + 10%
Solution:

Determine L: The L for this Converter is given by

V0 (1D min )
L= Ifs

36 Dr.L.Umanand, CEDT, IISc, Bangalore-560012

 iL VA
ig Io i t
L
L I
Vg VA io
R oVo L
C
i
g
DT (I-D)T

Fig. 3.4 Buck Converter and relevant waveforms

I is the current ripple in the inductor. Usually 10 to 25% of I0 is taken as I.

Take I = 10% of I0 ,

V0
and Dmin = Vg max

Substituting the appropriate values in the above equations, we find that

L = 0.1553 mH

Area product: The energy and area product calculations are as follows

E = 1/2 LI2 m
I
where Im = I0 + 2

Substituting the values in the above equations, we have

E = 2.14 x 10-3 joules

2E
Ap = AwAc = Kw K c JBm

take Bm = 0.2T for ferrite, J=3A/mm2 (3x106 A/m2),

Kc = 1 (for square wave) and Kw = 0.6.

Substituting the values in the area product equation, we have

Ap = 1.18888x10-8m4 = 11888.8mm4

Now choose the core from Appendix-I which has a Ap higher than the value
calculated above

P 36/22 is proper choice - (Ac = 201 mm2, Aw = 101 mm2, Ap = 20100 mm4 )

LI m
No. of turns: The equation for the number of turns is given by N = Ac B m

Dr.L.Umanand, CEDT, IISc, Bangalore-560012 37

 Substituting the values for the variables, we have N=21 turns (taking the next
higher integer if the calculation does not give an integer value).

Wire gauge: The gauge of the wire can be calculated from the equation given
below, taking

J = 3 A/mm2
I
a = J , where I = I0

Substituting the values of the variables in the above equation, we have,

a = 1.6666 mm2

Now choose the wire gauge from Appendix - II, which has a cross section area
greater than the value calculated above.

SWG 16 is a proper choice ( a = 2.075 mm2)

Cross check : The inequality AwKw > aN has to be checked.

So AwKw = 101 x 0.6 = 60.60 mm2 and aN = 2.075x21 = 43.57 mm2

So the inequality is satisfied, which means that the windings will fit into the
available window area.

Air gap Length: The air gap length, lg, is given by the equation,
2
0N Ac
lg = L , where 0 = 4 x 10-7 H/m.

Substituting the variable values to the above equation, we have,

lg = 0.717 x 10-3 m = 0.717 mm

3.5 SOME REMARKS ON INDUCTORS

The following remarks regarding inductor design are to be noted carefully.

As the permeability of the core is not a constant parameter and the energy
stored in the core material cannot be totally neglected, the above design
when implemented may not give the exact value of required L. However
this design procedure is satisfactory for most of the cases. The actual value
of desired L may have to be trimmed by adjusting the air gap.

The assembly of the core is done in a slightly different manner than that of
the transformer, when laminations are used to make the inductor. In the
case of the inductor, all E laminations are put together and all I laminations
are held together and air gap is put between the E laminations and the I

38 Dr.L.Umanand, CEDT, IISc, Bangalore-560012

 laminations. Thin Hylam / leatheroid / fibre glass/melinex can be used as air
gap. The assembly is then tightened by means of clamps.

In the case of potcores, EE and EI cores, a gap of lg/2 only need be intro-
duced in the centre to achieve effective air gap of lg, due to the geometry of
the core.

The inductor fabricated is not a pure L but has a resistance also. Its value
can be computed using the same procedure used in the case of
transformer. If there is a particular constraint on R (e.g. Low copper loss
requirement), then the wire size has to be chosen properly. One should not
forget to cross check the space requirement in case the wire size is altered.
Due to the copper losses, the actual energy handled by the core is slightly
higher than that given by equation 3.9. An efficiency factor can be incor-
porated in equation 3.15 so that the required Ap is slightly higher.

When using ferrite cores, once the core is chosen, calculation of the
number of turns is often simplified by using the so called AL value of the
core. AL value represents the inductance factor. The formula for the
number of turns is given by,

L = ALN2

When air gap is to be put, a ferrite core of pre-adjusted airgap can be

chosen and its AL value can be used in the design.

Dr.L.Umanand, CEDT, IISc, Bangalore-560012 39

 REFERENCES

1. L.Umanand and S.R.Bhat, Design of Magnetic Components for Switched

Mode Power Converters, Wiley Eastern Limited, 1992.

2. M.A.Nadkarni and S.R.Bhat, Pulse transformer: Design and fabrication,

CEDT series, Tata McGraw Hill Book Co., 1985.

3. Colonel Wm.T.McLyman, Transfomer and Inductor design handbook,

Marcel Dekker Inc., New York, 1978.

4. K.Kitsum, Switched mode power conversion - Basic theory and design,

Marcell Dekker Inc., 1984.

5. N.Radhakrishnan and S.R.Bhat, Design and technology of low power

transformers and inductors, CEDT, IISc., 1988.

6. McSay, Performance and design of alternating current machines, Sir Isaac

Pitman and Sons Ltd., 1962.

7. J.Nagarath and D.P.Kothari, Electric Machines, Tata McGraw Hill

Publishing Co. Ltd., New Delhi, 1985.

8. Philips Databook C5, Components and Materials, 1986, pp. 88.

40 Dr.L.Umanand, CEDT, IISc, Bangalore-560012

 APPENDIX - I

PHYSICAL, ELECTRICAL AND MAGNETIC CHARACTERISTICS

OF SOME FERRITE CORES

Cores mean mean core cross window area effective AL

without length magnetic section area, A w, product, relative nH/turns 2
airgap per turn, length lm , area A c , cm2 A p, cm4 permeab- +/- 25%
mm mm cm2 ility,r
+/-25%
POTCORES - CEL HP3C grade
P18/11 35.6 26 0.43 0.27 0.114 1,480 3,122
P26/16 52 37.5 0.94 0.53 0.498 1,670 5,247
P30/19 60 45.2 1.36 0.75 1.016 1,760 6,703
P36/22 73 53.2 2.01 1.01 2.01 2,030 9,500
P42/29 86 68.6 2.64 1.81 4.778 2,120 10,250
P66/56 130 123 7.15 5.18 37.03
EE CORES - CEL HP3C grade
E20/10/5 38 42.8 0.31 0.478 0.149 1,770 1,624
E25/9/6 51.2 48.8 0.4 0.78 0.312 1,840 1,895
E25/13/7 52 57.5 0.55 0.87 0.478 1,900 2,285
E30/15/7 56 66.9 0.597 1.19 0.71
E36/18/11 70.6 78 1.31 1.41 1.847 2,000 4,200
E42/21/9 77.6 108.5 1.07 2.56 2.739 2,100 2,613
E42/21/15 93 97.2 1.82 2.56 4.659 2,030 4,778
E42/21/20 99 98 2.35 2.56 6.016 2,058 6,231
E65/32/13 150 146.3 2.66 5.37 14.284 2,115 4,833
UU CORES
UU 15 44 48 0.32 0.59 1.19 1,100
UU 21 55 68 0.55 1.01 0.555 1,425
UU 23 64 74 0.61 1.36 0.823 1,425
UU 60 183 184 1.96 11.65 22.83 1,900
UU 100 29.3 308 6.45 29.14 187.95 3,325

Dr.L.Umanand, CEDT, IISc, Bangalore-560012 41

 Cores mean mean core cross window area effective AL
without length magnetic section area, A w, product, relative nH/turns 2
airgap per turn, length lm , area A c , cm2 A p, cm4 permeab- +/- 25%
mm mm cm 2
ility,r
+/-25%
TOROIDS - CEL HP3C grade
T 10 12.8 23.55 0.062 0.196 0.012 2,300 765
T 12 19.2 30.4 0.12 0.442 0.053 2,300 1,180
T 16 24.2 38.7 0.2 0.785 0.157 2,300 1,482
T 20 25.2 47.3 0.22 0.95 0.213 2,300 1,130
T 27 34.1 65.94 0.42 1.651 0.698 2,300 1,851
T 32 39.6 73 0.61 1.651 1.01 2,300 2,427
T 45 54.7 114.5 0.93 6.157 5.756 2,300 2,367

42 Dr.L.Umanand, CEDT, IISc, Bangalore-560012

 APPENDIX - II

WIRE SIZE TABLE

SWG Dia with enamel, Area of bare R/Km @20oC Weight

mm conductor, mm2 ohms Kg/Km
45 0.086 0.003973 4,340 0.0369
44 0.097 0.005189 3,323 0.0481
43 0.109 0.006567 2,626 0.061
42 0.119 0.008107 2,127 0.075
41 0.132 0.009810 1,758 0.0908
40 0.142 0.011675 1,477 0.1079
39 0.152 0.013700 1,258 0.1262
38 0.175 0.018240 945.2 0.1679
37 0.198 0.023430 735.9 0.2202
36 0.218 0.029270 589.1 0.2686
35 0.241 0.035750 482.2 0.3281
34 0.264 0.042890 402 0.3932
33 0.287 0.050670 340.3 0.465
32 0.307 0.059100 291.7 0.5408
31 0.33 0.06818 252.9 0.6245
30 0.351 0.07791 221.3 0.7121
29 0.384 0.09372 184 0.8559
28 0.417 0.11100 155.3 1.014
27 0.462 0.13630 126.5 1.245
26 0.505 0.16420 105 1.499
25 0.561 0.20270 85.1 1.851
24 0.612 0.24520 70.3 2.233
23 0.665 0.29190 59.1 2.655
22 0.77 0.39730 43.4 3.607
21 0.874 0.51890 33.2 4.702
20 0.978 0.65670 26.3 5.939
19 1.082 0.81070 21.3 7.324
18 1.293 1.16700 14.8 10.537

Dr.L.Umanand, CEDT, IISc, Bangalore-560012 43

 SWG Dia with enamel, Area of bare R/Km @20oC Weight
mm conductor, mm2 ohms Kg/Km
17 1.501 1.589 10.8 14.313
16 1.709 2.075 8.3 18.678
15 1.92 2.627 6.6 23.64
14 2.129 3.243 5.3 29.15
13 2.441 4.289 4 38.56
12 2.756 5.48 3.1 49.22
11 3.068 6.818 2.5 61
10 3.383 8.302 2.1 74
9 3.8 10.51 1.6 94
8 4.219 12.97 1.3 116

44 Dr.L.Umanand, CEDT, IISc, Bangalore-560012

 APPENDIX - III

TRANSFORMERS AND CHOKE LAMINATIONS - STANDARD

TYPES

TYPE No. A c , cm2 A w, cm2 A p, cm4

17 1.61 1.2 1.95
12A 2.52 1.884 4.75
21 2.52 3.32 8.36
10 2.52 4.43 11.2
10A 2.52 4.43 11.2
1 2.789 6.543 18.2
74 3.063 2.28 6.98
23 3.63 2.72 9.88
11 3.63 7.26 26.4
11A 3.63 9.07 32.9
2 3.63 10.89 39.52
30 4 3 12
31 4.94 3.71 18.3
45 4.94 3.71 18.3
15 6.45 4.84 31.2
44 6.45 4.84 31.2
14 6.45 6.55 42.2
4 6.45 15.85 102.2
33 7.84 5.88 46.1
3 10.08 7.54 76
13 10.08 14.11 142.3
4A 11.12 10.26 114
16 14.5 10.89 158
5 14.5 12.73 184.5
6 14.5 19.35 280.8
7 25.8 18.95 488.9
8 25.8 51.23 1,322
34 2.5 6.68 16.3

Dr.L.Umanand, CEDT, IISc, Bangalore-560012 45

 TYPE No. A c , cm2 A w, cm2 A p, cm4
9 4.4 9.1 44.9
9A 4.9 7.9 38.9
4AX 5.6 13.07 74.1
75 6.5 15.26 98.4
35A 14.5 39.34 570.4
8B 58.1 65.52 3,804
100 103.2 116.1 11,988

46 Dr.L.Umanand, CEDT, IISc, Bangalore-560012

 PROBLEMS

1. Derive the area product relationship for the half bridge converter, full
bridge converter, pushpull converter and the flyback converter
configurations.

2. Design a 50Hz transformer that has the following specifications:

The transformer has one primary and three secondary windings.
Primary voltage 230Vrms
Secondary ratings-1 140Vrms, 16A
Secondary ratings-2 12Vrms, 12A
Secondary ratings-3 12Vrms, 12A
Use CRGO laminations for the core. An operating flux density of 1.2T can
be chosen.

3. Design a 48mH inductor carrying 8Arms current used in a LC filter to filter

fullwave mains rectified waveform. Use CRGO laminations for the core
with operating flux density of 1.2T.

4. For a non-isolated buck converter, the inductance was calculated to be

1mH. The minimum load current is 0.5A and the maximum allowable load
current is 11A. Design the inductor for Bm = 0.25T, J=5A/mm2, Kw=0.6
and fs=40KHz.

5. Design a transformer for the half bridge converter configuration shown in

figure 2.2 for the following specifications,
output voltage, Vo 12V
output ripple, % 1% of Vo
output current, Io 3A
switching frequency, fs 20KHz
supply voltage, Vcc 24V +/- 10%

6. Design a transformer for the full bridge converter configuration shown in

figure 2.3 for the following specifications,
output voltage, Vo 12V
output ripple, % 1% of Vo
output current, Io 3A

Dr.L.Umanand, CEDT, IISc, Bangalore-560012 47

 switching frequency, fs 20KHz
supply voltage, Vcc 24V +/- 10%

7. Design a transformer for the push pull converter configuration shown in

figure 2.4 with the following specifications
output voltage, Vo 12V
output ripple, % 1% of Vo
output current, Io 3A
switching frequency, fs 20KHz
supply voltage, Vcc 24V +/- 10%

8. Design a transformer for the flyback converter (in the continuous conduc-
tion mode) with the following specifications
output voltage, Vo 12V
output ripple, % 1% of Vo
output current, Io 3A
switching frequency, fs 20KHz
supply voltage, Vcc 24V +/- 10%

9. Design a transformer for the flyback converter (in the discontinuous

conduction mode) with the following specifications
output voltage, Vo 12V
output ripple, % 1% of Vo
output current, Io 3A
switching frequency, fs 20KHz
supply voltage, Vcc 24V +/- 10%

10.Compare the physical sizes of the transformers obtained for the converter
configurations in problems (5) to (9). Comment on the preferred type of
converter configurations for various power ranges from the point of view of
transformer size.

48 Dr.L.Umanand, CEDT, IISc, Bangalore-560012