Post on 26-Mar-2022
Technical Presentation 2001 Roman Klinger, KB-PM K
MagAmp coresMagAmp cores
MagAmp CoresMagAmp CoresMain Applications:Main Applications:
Magnetics Quantitiy
+ +
+
0 / +
- / 0
0 / +
+ +
Technical Presentation 2001 Roman Klinger, KB-PM K
MagAmp coresMagAmp cores
Operation and Circuit principleOperation and Circuit principle
Forward Transformer(Master - Slave Type):
A Magnetic Amplifier is used to A Magnetic Amplifier is used to regulate the regulate the 2. and further output voltages2. and further output voltages of multiple of multiple output SMPSoutput SMPS‘‘s. s. It is an alternative to an electronic It is an alternative to an electronic regulation and consists of a regulation and consists of a soft magnetic soft magnetic core with a square hysteresis loopcore with a square hysteresis loop with with several no. of turns of copper wire (the core several no. of turns of copper wire (the core winding) and a winding) and a regulation circuitregulation circuit. The . The Magnetic Amplifier principle allows load Magnetic Amplifier principle allows load current regulation of several Amps with the current regulation of several Amps with the help of some 10 to 100 mA control current.help of some 10 to 100 mA control current.Small MagAmp cores are well introduced in Small MagAmp cores are well introduced in PCPC-- and server power supplies. The best and server power supplies. The best magnetic properties are achieved by magnetic properties are achieved by amorphous toroidal tapeamorphous toroidal tape--wound coreswound cores((VITROVAC 6025 ZVITROVAC 6025 Z)) or or nanocrystalline nanocrystalline VITROPERM 500 ZVITROPERM 500 Z..
Technical Presentation 2001 Roman Klinger, KB-PM K
MagAmp coresMagAmp cores
Current consumption of the 3.3 V Current consumption of the 3.3 V MagAmpMagAmp regulated output.regulated output.
current requirements of 3.3 V output of Desktop-PC SMPS
0
5
10
15
20
25
30
35
1998 1999 2000 2001
ATX Rev. 2.01Micro ATX Micro ATX, ATX 2.03
ATX 2.03, ATX 12V
Form Factor: ATX 2.01 Micro ATX ATX 2.03 ATX 12Vtotal Output Power (typ.): 200 W 120 – 145 W 200 – 250 W 300 W
typ. output current of 3.3 V: 12 A 8 A 14 A 30 A
Technical Presentation 2001 Roman Klinger, KB-PM K
MagAmp coresMagAmp cores
VAC core solutions:VAC core solutions:
AmorphousAmorphousVITROVAC 6025 ZVITROVAC 6025 Z
Nanocrystalline Nanocrystalline VITROPERM 500ZVITROPERM 500Z
Main Customer Benefits of VITROPERM 500Z cores:
• high squareness – enabling good regulation behaviour and reduced dead-time of MagAmp Choke
• very high induction swing - high magnetic flux in small core sizes
• extended temperature range up to 120°C
• best suitable for high current handling (reduction of copper losses be low no. of turns, thicker copper wire)
• cost advantage (Fe-based alloy)
reduction of weight, volume and costs
Main Customer Benefits of VITROPERM 500Z cores:
• high squareness – enabling good regulation behaviour and reduced dead-time of MagAmp Choke
• very high induction swing - high magnetic flux in small core sizes
• extended temperature range up to 120°C
• best suitable for high current handling (reduction of copper losses be low no. of turns, thicker copper wire)
• cost advantage (Fe-based alloy)
reduction of weight, volume and costsreduction of weight, volume and costs
Technical Presentation 2001 Roman Klinger, KB-PM K
MagAmp coresMagAmp coresM
ain
Ma t
eria
l Pro
per ti
esM
ain
Ma t
eria
l Pro
per ti
es
Technical Presentation 2001 Roman Klinger, KB-PM K
MagAmp coresMagAmp cores
Material Comparison: Material Comparison: Saturation Induction, SquarenessSaturation Induction, Squarenessamorphous VITROVAC 6025Zamorphous VITROVAC 6025Z -- nanocrystalline VITROPERM 500Znanocrystalline VITROPERM 500Z
Technical Presentation 2001 Roman Klinger, KB-PM K
MagAmp coresMagAmp cores
Material Comparison: Material Comparison: Core LossesCore Lossesamorphous VITROVAC 6025Zamorphous VITROVAC 6025Z -- nanocrystalline VITROPERM 500Z nanocrystalline VITROPERM 500Z -- ferriteferrite
Technical Presentation 2001 Roman Klinger, KB-PM K
MagAmp coresMagAmp cores
Nanocrystalline VITROPERM 500Z: NEW Type SeriesNanocrystalline VITROPERM 500ZNanocrystalline VITROPERM 500Z: : NEW Type Series
Core type series of nanocrystalline VITROPERM 500Z MagAmp coresfinished dimensions(limiting values)
corecross-section
meancorepathlength
coremass
totalflux 125°C
totalflux 190°C
corearea 2
product
eff. Cu-winding
area
meanCu-path
length
heattransferResis-tance
part number,order code
coredimensionsda,Core x di,Core xhCore
O.D. I.D. H AFe lFe mFe φss φss, 90°C Wa×AFe ACu lCu Rth
mm mm mm cm² cm g µWb µWb cm4 cm² cm K/W T6000...
10×7×4.5 11.7 5.5 6.1 0.054 2.67 1.1 12.7 11.9 0.013 0.059 2.27 57 6-E4010-W759
11×8×4.5 14.1 6.6 6.3 0.054 2.98 1.2 12.7 11.9 0.018 0.085 2.53 46 6-E4011-W760
12×8×4.5 14.1 6.6 6.3 0.072 3.14 1.7 16.9 15.8 0.025 0.085 2.53 46 6-E4012-W761
12.5×10×4.5 14.1 8.5 6.8 0.045 3.53 1.2 10.6 9.9 0.026 0.140 2.59 42 6-E4012-W762
16×10×6 18.0 8.0 8.1 0.144 4.08 4.3 33.8 31.7 0.072 0.124 3.25 34 6-E4016-W763
16.5×12.5×6 19.1 10.9 8.1 0.096 4.56 3.2 22.6 21.1 0.090 0.231 3.30 30 6-E4016-W764
17.5×12.5×6 19.1 10.9 8.1 0.120 4.71 4.2 28.8 26.4 0.112 0.231 3.30 30 6-E4017-W765
19×15.2×4.5 21.2 12.9 7.2 0.068 5.37 2.7 16.1 15.0 0.089 0.323 3.28 27 6-E4019-W766
20×15×8 22.6 10.3 10.2 0.160 5.50 6.5 37.6 35.2 0.133 0.206 4.08 26 6-E4020-W767
20×12.5×8 22.6 10.3 10.2 0.240 5.11 9.0 56.4 52.8 0.200 0.206 4.08 26 6-E4020-W768
Technical Presentation 2001 Roman Klinger, KB-PM K
MagAmp coresMagAmp cores
Amorphous VITROVAC 6025 ZAmorphous VITROVAC 6025 ZCore informations:
Our Mag Amp Cores are
preferably supplied in
plastic protective cases,
adding silicone rubber
(Fix 022). This finish is
suitable for direct winding
and offers optimum
mechanical protection for
the core, and thus the
best magnetic properties.
The resins used for the
plastic cases are
according to UL94V-0 or
UL94V-1. Epoxy coated
(Fix 350) core designs
aswell as many other core
sizes are available on
request.
VITROVAC 6025 Z cores for Mag Amps, standard sizes:coredimensions
finisheddimensions(limiting values)
corecross-section
meancorepathlength
coremass
totalflux 1
(25°C)
totalflux 1
(90°C)
eff.winding
area
meancopper
pathlength
heattrans.Res.
part number,order code
O.D. I.D. H AFe lFe mFe φss φss, 90°C ACu lCu Rth
mm mm mm cm² cm g µWb µWb cm² cm K/W T6000...
10×8×4 11.6 6.5 5.1 0.032 2.83 0.7 3.7 3.2 0.082 2.01 56 6-E4010-W534
10.1×6.9×4.5 11.6 5.5 6.0 0.058 2.67 1.2 6.7 5.8 0.059 2.24 57 6-E4010-W663
12.8×9.5×3.2 14.7 7.9 4.8 0.042 3.50 1.1 4.8 4.2 0.121 2.23 44 6-E4012-W464
12×8×4.5 14.0 6.6 6.2 0.07 3.14 1.7 8.1 7.0 0.085 2.45 47 6-E4012-W547
12.5×10×5 14.0 8.5 6.8 0.050 3.53 1.4 5.8 5.0 0.140 2.56 42 6-E4012-W535
14×8×4.5 15.5 6.5 5.7 0.108 3.46 2.9 12.4 10.8 0.082 2.53 44 6-E4014-W481
15.9×12.7×3.2 17.5 11.4 4.5 0.041 4.49 1.4 4.7 4.1 0.253 2.41 34 4-E4015-W6182
16×10×6 17.9 8.2 8.2 0.144 4.08 4.5 16.6 14.4 0.131 3.20 34 6-E4016-W536
17.5×12.5×6 19.1 10.9 8.1 0.120 4.71 4.4 13.8 12.0 0.231 3.30 30 6-E4017-W537
19.2×12.7×3.2 20.6 11.4 4.3 0.083 5.01 3.2 9.6 8.3 0.253 2.63 30 4-E4019-W6092
19×15×5 21.2 13.0 7.3 0.080 5.34 3.3 9.2 8.0 0.329 3.17 27 6-E4019-W539
19×15×10 21.2 13.0 12.3 0.160 5.34 6.6 18.4 16.0 0.329 4.25 24 6-E4019-W540
20×12.5×8 22.6 10.3 10.2 0.240 5.1 9.4 27.6 24.0 0.206 4.05 26 6-E4020-W538
1 Φss = 2×Bs×AFe2 epoxy coated
Technical Presentation 2001 Roman Klinger, KB-PM K
MagAmp coresMagAmp coresExamples:Examples:
VITROVAC 6025 Z VITROPERM 500 ZVITROVAC 6025 Z VITROPERM 500 Z
Server SMPS
(f=120 kHz): comparable regulation behaviour:
Server SMPS
(f=120 kHz): comparable regulation behaviour:
Core size: 16x10x6 mm 16x12.5x6 mmCore Weight: 4.5 g 3.0 gTmax in operation: 35 K 50 KPrice: 100 % ~ 70 %
Core size: 16x10x6 mm 16x12.5x6 mmCore Weight: 4.5 g 3.0 gTmax in operation: 35 K 50 KPrice: 100 % ~ 70 %
VITROVAC 6025 Z VITROPERM 500 ZVITROVAC 6025 Z VITROPERM 500 Z
Desktop-PC SMPS(100 kHz,
3.3 V, 30 Amax ):
Desktop-PC SMPS(100 kHz,
3.3 V, 30 Amax ):
Core size: 14x8x4.5 mm 11x8x4.5 mmCore Weight: 2.9 g 1.6 gNo. of turns N = 4 N = 5Price: 100 % ~ 40 %
Core size: 14x8x4.5 mm 11x8x4.5 mmCore Weight: 2.9 g 1.6 gNo. of turns N = 4 N = 5Price: 100 % ~ 40 %
•• less material (20 less material (20 -- > 50 %)> 50 %)•• smaller core sizessmaller core sizes•• cost down (10 cost down (10 -- > 50 %)> 50 %)
NanocrystallineNanocrystallineVITROPERM 500 ZVITROPERM 500 Z
Technical Presentation 2001 Roman Klinger, KB-PM K
MagAmp coresMagAmp cores
Further Design Examples:Further Design Examples:
DesktopDesktop--PC SMPS, 120 kHz, forward converter, short circuit proof designPC SMPS, 120 kHz, forward converter, short circuit proof designTTambamb = 40= 40°°C, C, ττ maxmax = 0.45= 0.45
Technical Presentation 2001 Roman Klinger, KB-PM K
MagAmp coresMagAmp cores
Material Comparison: Material Comparison: Reset Current Reset Current amorphous VITROVAC 6025Zamorphous VITROVAC 6025Z -- nanocrystalline VITROPERM 500Znanocrystalline VITROPERM 500Z
Technical Presentation 2001 Roman Klinger, KB-PM K
MagAmp coresMagAmp cores
Magnetic test specificationMagnetic test specification
Oscilloscope
Square wavepulsegenerator
i1
i1
Tong-test instrumentIntegrator
uc
R
COscilloscope
Core
Wattmeter(channel B, "current input")
Sine wavegenerator
i1
Core
Rm
um
u2
N2N1
RMS voltmeter,frequency counter,wattmeter(channel A,"voltage input")
1 2
Testing property Testing method Testing value
cased cores coated coresouter diameter> 12,5 mm:
outer diameter≤12,5 mm:
outer diameter> 12,5 mm:
outer diameter≤12,5 mm:
• squareness measurement of the residual flux
density swing ∆Brs from
remanence to saturation with
unipolar voltage pulses, fp = 1 kHz
≤ 50 mT ≤ 75 mT ≤ 80 mT ≤ 140 mT
• core losses
PFe
Measured with sinusoidal driving
voltage (f=50kHz) and flux density
amplitude Bmax = 0.4 T
≤ 65 W/kg ≤ 75 W/kg
1
2
VITROVAC 6025 Z (XCZ-500) VITROPERM 500 Z
< 150 mT
< 120 W/kg
Technical Presentation 2001 Roman Klinger, KB-PM K
MagAmp coresMagAmp coresC
alcu
latio
n fo
rmul
ae, V
ITR
OPE
RM
500
ZC
alcu
latio
n fo
rmul
ae, V
ITR
OPE
RM
500
ZDetermine wire current density S (typically 5 – 10 A/mm2)and calculate wire size and wire cross section aCu: aCu [mm2] =
I1,RMS [A]S [A/mm2]
Calculate regulation voltage UReg of MagAmp Choke: τmax = max. pulse duty ratio of primary switch, û1,min = peak value of transformer output voltage α = 1 for forward converters, α = 2 for push pull converters with 2 MagAmps
UReg [ V ] = α x τmax x û1,min [ V ]
Select core (start with small core) and calculate no. of turns:
N ≥10 x UReg [ V ]
α x 2.0 [ T ] x AFe [cm2 ] x f [ kHz ]
Check winding space Check winding space of selected coreof selected core ACu [cm2] ≥ aCu [cm2] x N
Calculate regulation fluxdensity swing ∆BReg ∆BReg [ T ] ≥
10 x UReg [ V ]α x N x AFe [cm2 ] x f [ kHz ]
∆BReg < (2 x BS) - ∆Brs
Estimate reset current IS:IS (mA) ≈
25 x ∆BReg [ T ]0.45 x f [ kHz ]0.53 x lFe [cm]N
Experimental Testing
∆TCu + ∆TFe < limit
nono
nono
nono
yesyes
yesyes
yesyes
Check Check temperature risetemperature rise
Select next bigger core
Increase N orselect nextbigger core
Increase N orselect nextbigger core
Calculate temperature riseof winding ∆TCu:(ρCu ≈ 2.27 x 10-6 Ωm)
and core ∆TFe: ∆TFe [ K ] = 420 x mFe [ g ] x Rth [ K/W ] x ∆BReg [ T ]1.5 x f [ kHz ]1.5
Rth [ K/W ] x I1,RMS [ A ]2 x N2 x lCu [cm] x ρCu [ Ωm ]∆TCu [ K ] = 20 x ACu [ cm2 ]
Design Software: Design Software: MagAmp CalculatorMagAmp Calculator
new programm version, Rev. 000104 betanew programm version, Rev. 000104 beta
for Microsoft Excel 97 / 2000for Microsoft Excel 97 / 2000
VITROVAC 6025 ZVITROVAC 6025 ZVITROPERM 500 ZVITROPERM 500 Z
Technical Presentation 2001 Roman Klinger, KB-PM K
MagAmp coresMagAmp cores
Design Software: Design Software: MagAmp CalculatorMagAmp Calculator
new programm version, Rev. 000104 betanew programm version, Rev. 000104 beta
NOTE: Enable Macros for full functionality. If disabled, the MagAmp Calculator does not operate properly.
Our Original Software is virus-checked.
Select Core Material for Calculation:
- amorphous VITROVAC 6025Z- nanocrystalline VITROPERM 500Z
Technical Presentation 2001 Roman Klinger, KB-PM K
MagAmp coresMagAmp cores
Design Software: Design Software: MagAmp CalculatorMagAmp Calculator
new programm version, Rev. 000104 betanew programm version, Rev. 000104 beta
Menu Bar
Circuit Principle(automaticallychanged by options on the leftscreen side)
Quick Result ViewerandDesign Change Buttons
INPUT fields for allapplication data(fill the white fieldsonly)
Core Selectionand AutoCalcButton
Material Display Bar
Technical Presentation 2001 Roman Klinger, KB-PM K
MagAmp coresMagAmp cores
• Press change core material (red) for calculation with Cores of VITROPERM 500Zand change core material (blue) for calculation with amorphous VITROVAC6025Z. This opens the following screen message:
CHANGE fieldforwindings
and back -Button