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September 2002
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Notice
The information contained in this document is subject to change without notice. Ansoft makes no warranty of any kind with regard to this material, including, but not limited to, the implied warranties of merchantability and fitness for a particular purpose. Ansoft shall not be liable for errors contained herein or for incidental or consequential damages in connection with the furnishing, performance, or use of this material. This document contains proprietary information which is protected by copyright. All rights are reserved. Ansoft Corporation Four Station Square Suite 200 Pittsburgh, PA 15219 (412) 261 - 3200 Microsoft Windows is a registered trademark of Microsoft Corporation. UNIX is a registered trademark of UNIX Systems Laboratories, Inc. Saber is a registered trademark of Synopsis Corporation. PSpice is a registered trademark of Cadence Corporation. PExprt, PEmag, Maxwell SPICE, SIMPLORER, and Maxwell 2D are registered trademarks of Ansoft Corporation.
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Printing History
New editions of this manual include material updated since the previous edition. The manual printing date, indicating the manuals current edition, changes when a new edition is printed. Minor corrections and updates incorporated at reprint do not cause the date to change. Update packages may be issued between editions and contain additional and/or replacement pages to be merged into the manual by the user. Pages which are rearranged because of changes on a previous page are not considered to be revised. Edition Date Software Revision 5.0
September 2002
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Typeface Conventions
Field Names Bold type is used for on-screen prompts, field names, and messages.
Keyboard Entries Bold type is used for entries that must be entered as specified. Example: Enter 0.005 in the Nonlinear Residual field. Menu Commands Bold type is used to display menu commands selected to perform a specific task. Menu levels are separated by a forward slash. For example, the instruction Choose File/Open means to choose the Open command on the File menu. Variable Names Italic type is used for keyboard entries when a name or variable must be typed in place of the words in italics. For example, the instruction copy filename means to type the word copy, to type a space, and then to type the name of a file, such as file1. Emphasis and Titles
Keyboard Keys
Italic type is used for emphasis and for the titles of manuals and other publications. Bold type, in a different font, is used for labeled keys on the computer keyboard. For example, the instruction Press Return means to press the key on the computer that is labeled Return.
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Installation
Before you use PExprt, you must: 1. 2. Set up your systems graphical windowing system. Install the Ansoft software, using the directions in the Ansoft PC Installation Guide.
If you have not yet done these steps, refer to the Ansoft installation guides and the documentation that came with your computer system, or ask your system administrator for help.
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Other References
For more information on PExprt commands and features, refer to the PExprt online help. To start PExprt, you must first access the Maxwell Control Panel. For more detailed information on the Maxwell Control Panel commands, refer to the Maxwell Control Panels online help system.
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Table of Contents
1.
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
General Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Sample Problem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Results to Expect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
2.
3.
Preferences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Specify Modeling Language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Specify Stock Libraries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
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4.
5.
6. 7.
8.
9.
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15.
16. 17.
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index-1
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Contents-4
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Introduction
Power Electronics Expert (PExprt) is an interactive, PC-based design tool that uses analytical expressions to design magnetic components such as transformers and inductors. For example, you can use PExprt to design both complex planar components and multi-winding flyback transformers. PExprt produces an optimal magnetic component design based on the waveform or electrical parameters you enter for the power converter and based on the cores, wires, and materials you select from a database. You only need to enter the numerical values, and PExprt automatically computes design alternatives. Rather than resulting in a single design alternative, PExprts output consists of a complete series of valid designs meeting your specified design objectives. These results can then be evaluated in terms of several criteria, including power loss and temperature rise. PExprt also includes PEmag, a powerful magnetic analysis module based on finite element analysis (FEA). This module conducts a detailed analysis of geometry, frequency, and material effects not considered by PExprt. The PEmag module also generates behavioral models for use in electrical simulators such as SIMPLORER, PSpice, or Saber. Using PExprt, you can:
Design inductors, multi-winding transformers, coupled inductors, and flyback type components. Introduce waveform or converter Data. Consider boost, buck, boost-buck, forward, push-pull, half-bridge, full-bridge, and flyback converters. Optimize constructive parameters, such as core size, core material, number of turns, air gap length, wire gage, and number of parallel turns. Calculate performance parameters, such as winding losses, core losses, flux density, DC and AC resistance, Irms currents, magnetizing inductance, leakage inductance, and temperature rise.
Introduction 1-1
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Consider complex effects, such as skin and proximity effects, fringing flux near the air-gap for energy calculations, and incremental permeability as a function of the field strength. Generate model netlists for Maxwell SPICE, PSpice, SIMPLORER, and Saber electrical simulators. Analyze the entire power electronics application of the resulting model, using an additional electrical simulator (PSpice, SIMPLORER, or Saber).
In this guide, you will use PExprt to model an inductor for a buck converter, an example that introduces you to the basic functions of the PExprt software. The goals for this chapter are to:
Understand the general procedure for creating an inductor design in PExprt. Review the sample problem and the procedure you will use to generate the design and obtain the design results.
1-2
Introduction
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General Procedure
General Procedure
To design a magnetic component in PExprt, follow this general procedure: 1. 2. 3. 4. 5. 6. 7. 8. 9. Select a design library from the list of stock libraries. Optionally, select cores, wires, and core materials from the design library. Only the selected elements are considered in the design process. Introduce the converter specifications. Optionally, specify design inputs, such as gap position, geometry, thermal constraints, wire spacing, maximum flux density, and maximum number of parallel turns. Optionally, select modeling inputs, such as winding losses and optimization criteria. Generate a list of possible designs that meet your specifications. Select a design, and explore one or more performance results, such as core losses, winding losses, or temperature rise. Select a design, and explore one or more constructive results, such as core size, core material, wire gauge, gap length, or number of turns. Use the Modeler menu to do the following:
Obtain a SIMPLORER, PSpice, Maxwell SPICE, or Saber subcircuit model of your selected design. Link with PEmag modeler in order to: Optimize the design by generating a new model using another winding strategy. Compare different winding strategies in order to reduce parasitics (leakage inductance, AC resistance, and capacitances). Quantify the effect of manufacturing tolerances or material tolerances. Perform sensitivity analyses. Analyze the impact of your design within the behavior of the entire circuit (voltage spikes, efficiency, and ringing).
10. Optionally, you can link with SIMPLORER to simulate the entire circuit.
Introduction
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Sample Problem
Sample Problem
In this guide, you will design, model, and simulate an inductor for a buck converter, using both wires and planar conductors. You will use the following specifications in your design.
Input Voltage: 42 V Output Voltage: 12 V Switching Frequency: 200 kHz Output Power: 300 W Current Ripple: 4.3 A (17 %)
This getting started guide takes you through the setup, design, and modeling of this magnetic component. You will cover the following steps: 1. 2. 3. 4. 5. Designing a low losses inductor from the converter specifications. Modeling the inductor using both an analytical-based and a FEA-based model, in order to analyze the impact of the fringing flux on the power losses. Simulating the entire converter, including the FEA-based model, with SIMPLORER. Designing a planar version of the inductor. Designing a toroidal version of the inductor. Select and optimize constructive parameters, including:
After setting up the problem and generating the solutions, you will do the following:
1-4
Core size Core material Number of turns Air gap length Wire gauge Number of parallel turns Winding losses
Introduction
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Sample Problem
Core losses Flux density DC and AC resistance Irms currents Magnetizing inductance Leakage inductance Temperature rise Skin and proximity effects Fringing flux nearby the air-gap for energy calculations Incremental permeability as a function of the field strength
Generate model netlists for the SIMPLORER electrical simulator. Analyze the entire power electronics application of the resulting model, using SIMPLORER.
Introduction
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Results to Expect
Results to Expect
The following eight figures show the type of results you can obtain using PExprt:
Input Data
Constructive Results
Performance Results
List of Results
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Results to Expect
Core data
AC Resistance
Time:
The total time needed to complete this getting started guide is approximately 3 hours.
Introduction
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Results to Expect
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Introduction
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This guide assumes that the following products have already been installed as described in the Ansoft and SIMPLORER installation guides:
Please see the Ansoft PC Installation Guide if you need to install or set up the software. The goals for this chapter are to:
Create a project directory in which to save the sample problems. Create a new project in that directory in which to save the buck inductor problem.
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See the Maxwell Control Panel online documentation for detailed descriptions of other options in the Maxwell Control Panel. If the Maxwell Control Panel does not appear, refer to the Ansoft PC Installation Guide for possible reasons. Next you will create a new project directory in which to store the projects for the PExprt Getting Started guides.
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The Project Manager appears, listing the current path and any existing projects.
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Note:
If you have already created a project directory while working through another PExprt getting started guide, skip to Create a New Project on page 2-6.
Warning:
To create the project directory: 1. Click Add from the Project Directories list at the bottom left of the Project Manager window. The Add a new project directory window appears, listing available directories and subdirectories.
2. 3.
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Double-click on the sub-directory names until the current directory (at the top of the window) is the one where you want to locate the project. Enter getstPExprt in the Alias field. An alias is a project directory name that refers to the curCreating a PExprt Project
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rent directory. You can use aliases to refer to project directories located in different computer directories, or across network drive locations. 4. 5. Click the Make New Directory radio button. Click OK. The new project directory, getstPExprt, appears in the Project Directories list under the current default project directory.
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2. 3. 4.
Enter BuckInductor in the Name field. Select Maxwell PExprt Version 5 from the Type pull-down list. The rest of the list displays other Ansoft products for which you have licenses. Enter your name or user ID in the Created By field.
5.
If you are using Microsoft Windows NT, 2000, or XP, your login name is automatically entered here. If you are using another version of Windows, you may enter your user name or leave the field as is.
Deselect the Open project upon creation check box, allowing you to create the new project without immediately launching the software. This allows you to enter project notes before opening the project. Click OK to create the new project. The project name appears in the list of projects in the getstart project directory. Because you created the project, the Status is set to Writable, indicating that you have access to the project.
6.
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Note:
You are now ready to open the new PExprt project and run PExprt.
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In the last chapter, you created the getstPExprt project directory and created the BuckInductor project within that directory. Now you will open that project in PExprt and start using the software. The goals for this chapter are to:
Open the project you just created and run PExprt. Learn about the PExprt working window. Specify your preferences modeling language, stock libraries, and units.
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2.
Click the + symbol in front of Converter Based to expand the Inductor/Converter Based
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tree. Three different types of converters appear in the tree: Buck, Boost, and Buck-Boost.
3.
Select the Buck converter type, and click OK. The PExprt working window appears.
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Libraries area
Waveforms tab: Use this tab to define the converter specifications and waveform inputs. Design Inputs tab: Use this tab to define the design inputs. Modeling Options tab: Use this tab to define the modeling options.
Use this area to define inputs and other specifications. When you change parameters in the Input/ Output Data area, the values for related parameters in that window are automatically updated. The graph is also automatically updated in the Graphical Information area.
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Libraries Area
The Libraries area contains a tree with the stock and design libraries used in PExprt. Each library contains cores, bobbins, wires, insulators, and core materials. To view the elements included in each library, click the + symbol to expand the tree.
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Preferences
Preferences
There are several options you can specify before working with PExprt. When you click Options/ Preferences, the Preferences window appears.
Modeling Language tab: Use this tab to specify the model language (Maxwell SPICE, PSpice, Saber, or SIMPLORER) to be used to write the model netlists. Stock Libraries tab: Use this tab to specify the libraries that you want to be opened with any new design.
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Preferences
2. 3.
Click the Simplorer button to select SIMPLORER as the modeling language. Click Apply or OK at the bottom of the window.
Note:
The first time you use PExprt, all the libraries included with PExprt are loaded. If you make any changes, they apply the next time you open a new document.
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Preferences
To specify the default libraries: 1. Click the Stock Libraries tab in the Preferences window.
2.
3.
To load a new stock library: a. Click Add New. The Browse Libraries window appears. b. Find and select the library you want to add, and click Open. The new library appears in the list. To remove a library from the list: a. Select a library from the Libraries to be loaded as Stock list. b. Click Remove. The library is removed from the list. The next time you open a PExprt design, the removed library does not appear in the Stock Library tree. Click OK at the bottom of the window. In this example project, you do not need to add or remove any libraries in the Preferences window.
4.
Note:
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Units of Measurement
Units of Measurement
You can also specify the unit of length you want to use in PExprt. For this example, you want to use millimeters. To specify millimeters as the unit of length: 1. Choose Options/Units. The Units window appears.
2.
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Units of Measurement
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PExprt Libraries
PExprt works with libraries in order to select elements (for example, cores, wires, core materials) that you want to be considered during the design process. The goals for this chapter are to:
Learn about the types of libraries available in PExprt. Work with PExprt libraries.
Time:
PExprt Libraries
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Types of Libraries
Types of Libraries
PExprt libraries contain the cores, bobbins, wires, and core materials needed to design magnetic components. Two different types of libraries are available in PExprt: stock libraries and design libraries. They are displayed in the Libraries area, in the lower-left portion of the PExprt working window.
Stock Libraries
Stock Libraries
These libraries are included with PExprt and are saved in the /PExprt_Install/Lib/PExprt directory, where PExprt_Install is the location where you installed PExprt. Seven libraries are provided with the PExprt installation: Ferroxcube (former Philips) Epcos (former Siemens) TDK Magnetics AVX Micrometals Steward Stock libraries are locked, and you cannot modify them. Once you drag a stock library into the design library folder, the new copy is editable, but the original stock library remains locked.
Design Library
A projects design library is the only library that is considered during the design process. All or part of the elements in this library are included during the design process. You specify a design library for your project by dragging one from the stock library tree in the Libraries area of the PExprt working window.
4-2 PExprt Libraries
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2. 3.
Use the browser to select the desired library. After you load a new stock library, that library appears under the Stock Libraries tree in the Libraries area.
PExprt Libraries
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2. 3.
Select the library you want to save from the list. Click OK.
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Click the Core Properties tab of this window to modify the effective values and thermal conductivity.
PExprt Libraries
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Click the Dimensions tab to modify the dimensions of this particular core.
2.
Bobbins: When you double-click a bobbin, a properties window for that element appears:
3.
Use this window to modify the dimensions and thermal conductivity for the selected bobbin.
Wires: When you double-click a wire (for example a SOLID one), a properties window for
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PExprt Libraries
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4.
Use this window to modify the dimensions and thermal conductivity for the selected wire.
Material: When you double-click a core materials, a properties window appears for that element:
Click the Electrical Properties tab of this window to modify the electrical parameters. Click the Additional Parameters tab to introduce the losses parameters, thermal conductivity, and dependency of the permeability with the magnetic field strength, as shown
PExprt Libraries
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below:
Click the Graphical Information tab to graphically represent the incremental permeability, core losses and the B-H curve, as shown below:
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PExprt Libraries
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A new PQ core, named New Core, appears at the end of the PQ cores list.
Note:
Elements are copied element by element; you cannot copy an entire type of elements. For example, it is not possible to copy all ETD cores from one of the stock libraries by dragging the ETD label. You must copy each individual ETD core.
PExprt Libraries
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PExprt Libraries
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In Chapter 3 you opened the BuckInductor project, explored the PExprt working window, and reviewed the general procedure for creating a magnetic component design with PExprt. In Chapter 4 you learned how to work with PExprt libraries. You are now ready to start defining the project for the buck inductor design; the first step is to define the design library. The goals for this chapter are to:
Understand the role of the design library in the design process. Define the design library for the buck inductor sample project.
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Define design constrains selecting part or only one of the cores, wires, and core materials contained in the design library. Consider multiple combinations of the various cores, wires, and core materials contained in the design library.
The design library is the library that contains the elements considered for the final design. Any element not included the design library is ignored during the design process. You can select the elements you want to include in the design library or allow PExprt to automatically select the elements for you, based on encoded design criteria described later. See the section Auto-Select Feature on page 5-5 for more information on how PExprt selects elements for you.
Drag the Ferroxcube library from the Stock Library tree folder, and drop it onto the Design Library tree folder.
A copy of Ferroxcube library, named Ferroxcube_Design, appears under the Design Library tree.
Note:
The stock libraries included with PExprt are locked and cannot be modified. Any library created by the user can be modified. Once you copy a stock library, into the design library folder, you can then modify the copied version.
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2. 3.
Right-click the RM label. A shortcut menu appears. Select Select All from the shortcut menu.
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The RM icon turns green, indicating that part or all the RM sizes have been selected. 4. 5. Expand the POT folder by clicking its + symbol. Right-click each of the following elements under POT:
A tool icon appears next to each element that has been selected (which is done by right-clicking).
You could repeat steps 4 and 5 to select wires and core materials from the design library, but will allow PExprt to use the Auto-select feature to specify those elements.
Note:
The bobbins are automatically selected once you have selected the cores. Only the bobbins with the same name than the cores are selected.
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Auto-Select Feature
If you do not select elements on your own from the design library, PExprt can do so for you using its AutoSelect feature. The Auto-Select feature is applied just before starting the design procedure, immediately after you click Calculations/Start Design Process. PExprts Auto-Select feature applies the following default selection criteria when selecting elements:
Core Shapes:
Note:
Inductors and Coupled Inductors: POT, RM, EE, and EP Transformers and Flyback: RM, EE, and ETD Planar components: RM, EE, and EI Toroidal components: Toroids PExprt selects the size of the cores based on the power handled by the component. PExprt selects solid cylindrical wires for concentric and toroidal designs, and selects toroidal designs and planar conductors for planar designs. and planar conductors for planar designs. PExprt selects one out of every three wires so that different diameters may be considered. PExprt selects a maximum of three core materials, based on the frequency and amplitude of the first harmonic of the current waveform and its DC level. If the current design library does not contain bobbins for the selected cores, the core shapes and sizes are selected according to the bobbin shapes and sizes of the design library.
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After you have selected the design library and the elements to be considered during the design process, you need to introduce the converter specifications. Converter specifications include input and output voltage, switching frequency, and current ripple. The goal for this chapter is to:
Time:
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2. 3. 4. 5. 6. 7.
Enter 42 in the Input Voltage field, and select V as the units. Enter 200 in the Switching Frequency field, and select kHz as the units. Enter 12 in the Voltage field under Output Values, and select V as the units. Enter 300 in the Power field under Output Values, and select W as the units. Enter 4.29 in the Ripple Value field under Inductor Current Ripple, and select A as the units. Choose File/Save to save the project. Accept the default location for the project file, and choose Save.
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Note:
The current ripple can be introduced either by the absolute value or by the percentage with respect the average current. When you introduce the value using one of these approaches, the other value is automatically updated when you refocus. The non-editable values are updated each time you enter a value in the editable boxes and refocus.
Note:
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PExprt is designed to automatically switch between continuous and discontinuous conduction mode as a function of the converter specifications. For example, if you introduce 20 W as the value for the output power in the previous example, the waveforms change to discontinuous conduction mode.
If you try this, remember to change the output power back to 300 W in order to continue with this example.
6-4 Converter Input Data
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Design Inputs
After you have selected the design library and introduced the specifications for the converter, as described in Chapter 6, Converter Input Data, you are ready to design the component and can go on to Chapter 9, List of Results. However, before you do so, you may want to customize your design by introducing several optional design inputs. The goal for this chapter is to:
Time:
Design Inputs
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2.
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Design Inputs
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Design Parameters
The Design Inputs tab is shown below with the default values:
Design Impact
Since the fringing energy of the gap can be considered during the design process, the position of the gap determines the value of the gap length. When you select None, PExprt tries to meet the specifications with no gap inclusion.
Geometry
The selected geometry type is applied for the design. When you select this option, PExprt considers the permeability constant or a function of the magnetic field strength. You can change whether or not the permeability depends on H through the Core Material elements of the design library. This value determines the film coefficient for the radiation of temperature. Low means close environment, while High means forced ventilation. When you select Low, you obtain a higher temperature rise than when you select High for the same specifications.
Ventilation Type
Design Inputs
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Bobbin
Include
If this option is not selected, PExprt presents designs with no bobbin. By default, concentric components include a bobbin, and planar components do not include a bobbin. Toroidal components never include a bobbin. This parameter determines the most feasible winding strategy in order to create the setup you specify (i.e., to create a 1D analytical-based model or a 2D FEA-based model). The following types of models are available:
Winding Setup
2D Winding Strategy: PExprt allows more than one winding in the same layer. For example, two parallel windings may be placed in the same layer. 1D Completely-Full: PExprt fills the layers with turns, filling the entire window height. 1D Partially-Full: PExprt allows layers partially filled with turns.
Winding Efficiency Awire/Awinding (Wire area/ Winding area) Spacing
The parameter determines how to modify the wire spacing. The worse the winding spacing, the lower the number of wires that fit in the window.
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Design Inputs
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If this check box is selected, PExprt considers the energy around the air gap region (fringing energy) for the air gap length calculation. If the design has no air gap, this parameter is irrelevant. PExprt presents solutions with the specified top and central margin tape percentages, as shown below:
Margin Tapes
Maximum Temperature Rise Bsat/Bmax: This value is specified as a percentage of the saturation flux density. (PExprt is not designed to provide components working above saturation value of the flux density.) Maximum Gap: This value is specified as a percentage of the window height. Maximum Parallel Turns Maximum Number of Layers: This value is particularly useful in the design of planar components, where the cost of the components depends strongly on the number of layers.
PExprt presents solutions with a temperature rise below the Maximum Temperature Rise value. Bsat/Bmax is the maximum value of flux density PExprt considers for the calculations. PExprt presents solutions with a gap length below the Maximum Gap value. PExprt uses the Maximum Parallel Turns value for the maximum number of parallel windings to be considered during the design process. PExprt uses the Maximum Number of Layers value for the maximum number of layers to be considered during the design process.
Design Inputs
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Design Inputs
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Modeling Inputs
After you have selected the design library and introduced the specifications of the converter, as described in Chapter 6, Converter Input Data, you are ready to design the component and can go on to Chapter 9, List of Results. However, before you do so, you may want to introduce several optional modeling options, in order to improve the accuracy of the results. The goal for this chapter is to:
Time:
Modeling Inputs
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2.
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Modeling Inputs
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Modeling Parameters
The Modeling Options tab is shown below with the default values:
Design Impact
During the design process, there are three possible ways to calculate the losses in the conductors: Irms and DC Resistance: Winding losses are calculated as: P = I2rms * RDC Harmonics and AC Resistance (Skin): Winding losses are calculated as: P = I2DC * RDC + I2rms_1 * RAC_1 + I2rms_2 * RAC_2 + I2rms_3* RAC_3 + ... (where Irms_i is the rms value of the harmonic i, and RAC_i is the resistance at the frequency of the harmonic i calculated with the effective area, accounting for the skin effect at each frequency). Harmonics and AC Resistance (Dowell): Winding losses are calculated as: P = I2DC * RDC + I2rms_1 * RAC_1 + I2rms_2 * RAC_2 + I2rms_3 * RAC_3 + ... (where Irms_i is the rms value of the harmonic i, and RAC_i is the resistance at the frequency of the harmonic i, calculated with the Dowell equations).
If you account for the Harmonics in the losses calculation, you can specify how many harmonics you want to be considered during the design process. You can introduce this information specifying the number of harmonics or by means of the relative influence of one harmonic with respect to the previous one.
Modeling Inputs
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If you select No Optimization, PExprt does not iterate to find the lower losses solution for each combination of core/wire/material. If you select Apply Optimization, PExprt optimizes using two possible approaches (Mode 1 or Mode 2). Click More Info to learn more about the two approaches.
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Modeling Inputs
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List of Results
PExprt calculates all solutions meeting the initial specifications, but you can configure which ones to present. If you select Show all solutions, PExprt shows all meeting specifications. If you select Selection, only those that meet the selection criteria are included on the List of Results tab. To modify the default selection criteria, click the Select Solutions button. In the window that appears, you can specify how the results will be classified (by loss, temperature rise, height, or footprint) and the number of solutions to be shown. If you want to use all the elements you have selected in the design library for the design process, select No Restrictions. However, if you have selected many elements in the design library, and you do not know how many of them make sense to be considered in the design, select Apply Restrictions to allow PExprt to select the appropriate elements for your design. You can configure how restrictive the criteria are for the selection by clicking the Configure button. In the window that appears, use the Design Constraints tab to set the restriction level for the selections. To learn more about how PExprt applies restrictions, click the Information tab.
Selection of Apply Restrictions elements No Restriction (all possible from the configurations) Design Library
Modeling Inputs
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List of Results
You are now ready to generate designs and explore the solution results. The goals for this chapter are to:
Generate the design alternatives. Classify the designs using the List of Results tab in the Input/Output Data area of the PExprt working window.
Time:
List of Results
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3.
When the design process is complete, a design report message appears, telling you how many valid designs were obtained from the total number of analyzed designs. In this particular case, PExprt tells you it has obtained 128 valid results out of 1370 analyzed designs. Since you selected Solution Selection on the Modeling Options tab, only the 10 best solutions, in terms of losses, are shown. Click OK to dismiss this window. The list of results appears on the List of Results tab of the
4.
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List of Results
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List of Results
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Do the following to configure the List of Results tab: 1. Click on the header of one of the columns to either:
Note:
Classify that column in ascending or descending order. Select that particular column to be graphically represented in the Graphical Information area. The columns containing alphanumerical values will not be graphically represented.
2.
Double-click on any of the designs in the list. The Customize List of Results window appears.
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List of Results
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3.
Show or hide columns Specify the range of values to represent elements in each column.
To present solutions with a gap larger than 1 mm, enter 1 in the Gap field as the minimum gap length.
4.
The List of Results tab presents only solutions with a gap larger than 1 mm, as can be seen below.
5. 6.
Right-click on one of the designs of the List of Results tab, for example, the first one. A shortcut menu appears. Select Copy to My Results from the shortcut menu, as shown below:
A new tab, named My Results, appears in the Input/Output Data area. This tab contains any designs you copied there, as in steps 4 and 5. 7. Click the My Results tab to check that the design specified in steps 4 and 5 is now copied in
List of Results
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Note:
When you save a project using File/Save, File/ Save As, or the toolbar button, the only designs saved with the project are those on the My Results tab. Designs on the List of Results tab window are not saved.
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List of Results
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See PExprt Working Window on page 3-4 for a description of the working window.
List of Results
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9-8
List of Results
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Performance Results
After generating various designs for this particular example, you are now ready to explore the results that PExprt provides for each design on the List of Results tab. The goal for this chapter is to:
Time:
Performance Results
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Note:
To reverse the order (ascending/descending), click a second time on the column header.
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Performance Results
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3.
4.
Note:
The results presented on the Performance Results tab correspond only to the design currently selected on the List of Results or My Results tabs.
Performance Results
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Input/Output Data area: This area is used to show the numerical values of the performance results.
Graphical Information area: This area is used to graphically represent the following parameters:
Power Losses distribution: This parameter represents the ratio between core losses and wire losses. Window Filling: This parameter represents the ratio between the total wire area in the window and the total air area in the window. Window Rate: This parameter represents the ratio between the total winding area (area of the window where the winding is placed, included the air among turns) and the area of the window where there is not any winding.
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Performance Results
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The following performance results parameters are shown on the Performance Results tab in the Input/Output Data area of the PExprt working window: 1. Losses considering selected model:
Core: This performance results parameter represents the losses in the core of the magnetic component under the defined working conditions. To explore the core losses in more detail, click on the core losses value display, which is also a button. When you click this button, the Core Losses window appears, describing how the core losses are calculated (using the Steinmetz equation).
Winding: This performance results parameter represents the losses in the winding, applying the model that you selected on the Modeling Options tab. In this example, you are considering the skin effect of each harmonic. To explore the winding losses in more detail, click on the winding losses value. The Winding AC Information window appears, dis-
Performance Results
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You can change the frequency range of the plot using the Min Freq. and Max Freq. fields. Click the AC Losses tab to plot the contribution of each harmonic to the total winding losses.
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Performance Results
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Click the Current FFT tab to plot the Fast Fourier Transformation of the current waveform. This information represents the harmonic content of the current waveform.
2.
Total: This performance results parameter represents the total of the core and winding losses added together.
Winding DC losses:
DC Resistance: This performance results parameter represents the DC resistance of the winding. To explore the DC resistance in more detail, click on the DC Resistance value or
Performance Results
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Irms: This performance results parameter represents the root medium square (rms) value of the current waveform. DC Losses: This performance results parameter represents the DC losses in the windings under the defined current waveform. To learn about how this value is calculated, click on the DC Losses value. The Winding DC Information window appears, listing a detailed explanation about the DC losses calculation.
3.
Window Occupancy:
Window Filling: This performance results parameter represents the ratio between the total wire area in the window and the total air area in the window. Window Rate: This performance results parameter represents the ratio between the total winding area (area of the window where the winding is placed, including the air among turns) and the area of the window where there is no winding.
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Performance Results
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4.
Additional Parameters:
5.
Current Density: This performance results parameter represents current density in the winding (rms current value divided by the cross section area of the wire). Parallel wires are taken into account. Inductance: This performance results parameter represents the inductance of the final design. PExprt tries to fit this value to the specified one. Temperature Rise: This performance results parameter represents the temperature rise (difference of temperature between the external air and the hottest point) in degrees centigrade.
Flux Density:
Note:
Variation of B: This performance results parameter represents the variation of the flux density in mT (teslas * 10-3). Maximum B: This performance results parameter represents the maximum value of the flux density in mT (teslas * 10-3). PExprt is not designed to provide designs above saturation flux density. Therefore, the maximum B value always presents a value below the saturation B value.
Performance Results
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6.
Incremental Permeability:
Havg: This performance results parameter represents the average value of the Magnetic Field Strength in Amperes/meter. Permeability: This performance results parameter represents the value of the permeability that has been used in the current design. Initial Actual This is the initial value of the relative permeability defined in the Core Material library for this particular core material. This is the actual value of the relative permeability used in the design process, which accounts for the DC flux level. Since in this example you have not considered the DC flux level in the permeability value, this value is the same as the initial permeability.
Note:
To account for the DC flux level in the permeability calculation, you need to select the Permeability as a function of H check box on the Design Inputs tab.
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Performance Results
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Constructive Results
By now you have generated the designs for this particular example, and you have explored the Performance Results tab in the Input/Output Data area of the PExprt working window. You are now ready to explore the Constructive Results tab, which PExprt provides for each design on the List of Results tab. The goal for this chapter is to:
Time:
Constructive Results
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Click the Constructive Results tab in the Input/Output Data area of the PExprt working window.
The following window appears, displaying the Constructive Results tab in the Input/Output Data area and the cross-section of the current design in the Graphical Information area:
Note:
The results presented on the Constructive Results tab correspond to only one design -- the design that is currently selected on either the List of Results tab or the My Results tab.
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Constructive Results
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The following constructive results parameters are shown on the Constructive Results tab in the Input/Output Data area of the PExprt working window: 1. Component:
2.
Core Size: This parameter represents the core size and name for the selected design. Bobbin: This parameter represents the bobbin size and name for the selected design. Core Material: This parameter represents the core material name for the selected design. Wire: This parameter represents the wire gauge (AWG) and name for the selected design. Library: This parameter represents the name of the library that has been used as the design library for the selected design.
Parameters:
Gap: This parameter represents the air gap length for the selected design. Number of Turns: This parameter represents the number of turns for the selected design. Parallel Turns: This parameter represents number of parallel turns for the selected design.
Constructive Results
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Constructive Results
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PExprt includes an advanced modeling package that enables you to create accurate models of the generated designs. The modeling module, called PEmag, allows you to generate analytical-based or finite element-based models. You can link directly between the design module (PExprt) and the modeling module (PEmag), as described in Chapter 14, Using PExprt with PEmag. However, if you want to quickly generate an analytical model of your design without opening PEmag, you can use the modeling feature of PExprt, which uses the same modeling generation engine as PEmag analytical model. Since the modeling strategy applied to generate the model is based on analytical expressions, only magnetic component designs that present a one-dimensional (1D) field distribution can be modeled using this approach. Therefore, this feature is only enabled if the selected design presents a 1D field distribution.
Note:
Magnetic components with a single conductive sublayer in each layer can be modeled using an analytical-based model. If the magnetic component contains more than one conductive sublayer per layer, only FEA-based modeling can be used through PEmag. If the modeling feature is grayed-out, then the selected design cannot be modeled using analytical expressions. The influence of the fringing flux in components with an air gap is a clear 2D effect. Although the analytical-based model accounts for the energy around the air gap, the influence of this effect on the resistance is not considered in the analytical model approach.
Note:
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Note:
You can force PExprt to provide 1D designs using the Winding Setup parameter on the Design Inputs tab.
Since the selected design in this example presents a 1D field distribution, you can generate the analytical model from PExprt without forcing PExprt to do so. The goals for this chapter are to:
Define the model language (Maxwell SPICE, PSpice, Saber, or SIMPLORER). Generate the analytical-based model.
Time:
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2. 3.
Click Simplorer to select it as the as modeling language. Click OK to apply the selection and close the window.
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You can now use this model in SIMPLORER as any other circuit element. See Chapter 15, Linking with SIMPLORER for additional information. To explore the model netlist: 1. Click the Modeler/View Analytical Model Netlist/Simplorer menu option. Windows Notepad opens, displaying the SIMPLORER netlist description.
2.
When you are finished viewing the netlist description, click File/Exit to exit Notepad.
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Analysis Mode
So far you have been working with PExprt in Design Mode. An alternative way to work with PExprt is called Analysis Mode. Analysis Mode works with only a single design, which you select from the List of Results tab. Once you have selected a design, you may want to change a particular parameter of this design and then evaluate the impact of this change on the performance results. This can be done using Analysis Mode. You can also use Analysis Mode to evaluate previous designs with PExprt. In other words, if you have previously designed a magnetic component and you want to evaluate the losses, temperature rise, and other factors of this design, you can use Analysis Mode to introduce this design and then obtain its performance results. The goal for this chapter is to:
Time:
Analysis Mode
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To select Analysis Mode: 1. Click Calculations/Analysis Mode. Since you previously copied a design to the My Results tab, in Using the List of Results Tab on page 9-4, a message appears telling you the designs on that tab will be deleted. Click Yes to continue. The Constructive Results tab appears, showing the cross-section of the selected design. You can edit several values on the Constructive Results tab: the gap length, the number of turns, and the number of parallel turns. There is no design library when working in Analysis Mode. Therefore, the Design Library folder in the library tree is hidden while you are working in this mode.
2.
Note:
To modify one of the constructive results values in order to evaluate its impact on the design: 1. Change the Gap to 1 mm (instead of the current 1.26 mm in the gap length box).
2.
Click Calculations/Analyze Component to evaluate the results. Since you previously generated an analytical model for the current project, a message appears, asking you if you want to remove that model. Click Yes to remove the previously generated model. The Performance Results tab appears, showing the results for the modified design.
3.
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Analysis Mode
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Reducing the gap length from 1.26 mm to 1 mm has modified the inductance from 10 H in the original design to 12.24 H in the modified design. You can modify all of the constructive parameters by working in Analysis Mode. Do the following to modify the remaining of the constructive parameters: 1. Click the Constructive Results tab. 2. Click the Cores tab in the Libraries area.
3. 4. 5.
Expand the Ferroxcube library. Expand the RM core type. Drag the RM12/I core, and drop it on the area where the cross-section of the magnetic component is represented (in the Graphical Information area). The new core is represented as shown below:
6. 7. 8. 9.
Click the Bobbins tab in the Libraries area. Expand the Ferroxcube library. Expand the RM bobbin type. Drag the RM12/I bobbin, and drop it on the area where the cross-section of the magnetic com-
Analysis Mode
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10. Click the Wires tab in the Libraries area. 11. Expand the Ferroxcube library, and then expand the SOLID wire type. 12. Drag the AWG15 wire, and drop it on the area where the cross-section of the magnetic component is represented. The new cross-section is represented as shown below:
After modifying the constructive parameters, save the project and evaluate the results. To save the project: Click File/Save. To evaluate the results: Click Calculations/Analyze Component. The Performance Results tab appears, showing the results for the modified design.
Note:
If you save the project while working in Analysis Mode, the project is saved in this mode, along with any design modifications you have applied to the selected design.
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Analysis Mode
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As already mentioned, the PExprt package includes a powerful modeling module, PEmag, which allows you to generate models of the designs created using PExprt. PEmag allows you to modify the winding setup of the current design in order to evaluate the impact of different constructive parameters. Using PEmag you can:
Optimize the design by generating a new model using another winding strategy. Compare different winding strategies in order to reduce parasitics (leakage inductance, AC resistance, and capacitances). Quantify the effect of the manufacturing tolerances. Quantify the effect of the material tolerances. Perform sensitivity analyses. Analyze the impact of your design on the behavior of the entire circuit (voltage spikes, efficiency, and ringing).
You can work with PEmag as an additional add-on module within PExprt or as a standalone application.
Note:
Refer to the PEmag Getting Started Guides to learn how to use PEmag in detail.
Time:
Link PExprt with PEmag. Extract information from the model generated with PEmag. This chapter should take approximately 10 minutes to work through.
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Invoking PEmag
Invoking PEmag
You can only invoke PEmag after you have generated the List of Results tab and selected a design from the list. To invoke PEmag: 1. Click the Modeler/Invoke PEmag Modeler menu option. An information message appears telling you that you are exporting the selected design to the PExprt Modeling Module (PEmag). Nonlinear parameters are not exported to PEmag; therefore, if you need to generate models with nonlinear cores in PEmag, you need to introduce the nonlinear core parameters before generating the model. Click OK to dismiss this window.
2.
Since you are working in Analysis Mode, PEmag opens the current design that you previously modified, as shown below:
To evaluate the impact of the fringing flux around the air gap region in your PExprt design, you need to generate the finite element-based (FEA-based) PEmag model.
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3.
Click the Start button to start the model procedure. The model takes 1 minute and 30 seconds to generate on a 2-GHz Pentium 4 computer. A message appears, telling you the parameter extraction is complete.
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4.
5. 6. 7.
Click the Exit button in the UPM Mgen window. Click Yes when you are asked if you want to exit. Click the Exit button to exit the UPM FEA Modeler window.
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Since you have generated the model of the current design using the Maxwell 2D Finite Element solver, this model accounts for 2D effects such as the losses due to the fringing flux around the gap region. 8. Select File/Exit to close PEmag and return to PExprt. In your current PExprt design, you will now evaluate the impact of these additional losses due to the fringing flux.
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2.
Select PEmag FEA based Model from the Winding Losses Calculation section. The PEmag Analytical Model and PEmag FEA based Model options are disabled if the PEmag model has not been previously generated.
Note:
3.
Click Calculations/Analyze Component to evaluate the results. An information window appears, telling you that the waveform may change because PExprt uses the AC resistance and Magnetizing Inductance information from the PEmag FEA based model. Click OK to dismiss this window. The Performance Results tab appears, showing the results.
4.
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If you select Harmonics and AC Resistance (Skin) on the Modeling Options tab for this design, you obtain the losses shown below:
However, if you select PEmag FEA based Model on the Modeling Options tab for this design, you obtain the losses shown below:
In this particular example, the impact of the fringing flux on the losses is about 170 mW.
14-7
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14-8
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The analytical-based and FEA-models generated using PExprt and PEmag can be linked to different electrical simulators in order to simulate the behavior of the entire circuit. Ansoft SIMPLORER is one electrical simulator that can be used as part of an entire design package. The combination of PExprt, PEmag, and SIMPLORER provides a unique, powerful way to design, model, and simulate electromagnetic systems. The goal for this chapter is to:
Note:
Use SIMPLORER to simulate the behavior of the entire circuit. Refer to the SIMPLORER User Guide to learn how to use the software in detail.
Time:
15-1
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2. 3.
Click Simplorer to select is as the modeling language. Click OK to apply the selection and close the window.
15-2
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You are now ready to open SIMPLORER and use the generated model as part of your circuit.
15-3
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5.
Use the browser to access the /PExprt_Install/Template/Simplorer/Library directory, where PExprt_Install is the location where you installed PExprt.
15-4
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6.
Select the PExprt.smd library, and click Open. The PExprt library appears on the User tab.
Note:
Steps 3 through 6 should only be performed once. The next time you open SIMPLORER, the PExprt library is automatically loaded.
7. 8.
Click File/New on the SIMPLORER menu to create an empty schematic. Select the User6 library from the Users in the ModelTree area. If you do not have a User6 library, you can create your own user library.
Note:
9.
Right-click in the blank area below the library names. A shortcut menu appears.
15-5
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11. Use the browser to access the directory where you saved the PExprt analytical project. 12. Select buckinductor.sml file, and click Open. The Insert Macro window appears.
13. In the Insert Macro window, click on the buckinductor element of the tree and then click OK. The new model (buckinductor) appears in the ModelTree area.
14. Drag the model from the ModelTree area, and drop it in the schematic area.
Note:
You use the FEA-based model in SIMPLORER in the same way, selecting the FEA-based model instead of the analytical one in steps 12 and 13.
15-6
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More designs are beginning to use planar magnetic components, and PExprt has been designed to work with planar designs using the same philosophy as wire components. The goal for this chapter is to:
Repeat the design of the buck inductor, this time using planar technology.
Time:
16-1
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5.
To change the Spacing to reasonable values for a planar design, enter 150 m in the Intralayer field and 200 m in the Inter-layer field.
6.
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To select appropriate core shapes for a planar design: 1. Click the Cores tab in the Libraries area, and expand the Ferroxcube_Design library.
2. 3. 4.
Right-click on the POT type, and select Unselect All from the shortcut menu. The POT label now appears in gray, indicating there are no cores selected for that type. Right-click on the RM type, and select Unselect All from the shortcut menu. The RM label now appears in gray, indicating there are no cores selected for that type. Expand the RM core type, and right-click to select the RM12/ILP and RM14/ILP cores. (LP stands for Low Profile.) A "tool" icon appears in front of each selected core, as shown below.
5.
16-3
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To start the design process for this planar component: 1. Click Calculations/Start Design Process. The Auto-Select feature is applied for the planar wires parameter. A message appears, asking if you want to allow PExprt to auto-select the wires. Click Yes to have PExprt automatically select the wires. The design process begins. When the design process has completed, a design report message appears, telling you how many valid designs have been obtained from the total number of designs analyzed. In this particular case, PExprt tells you it has obtained 30 valid results out of 200 analyzed designs. Since you specified Solution Selection on the Modeling Options tab, only the best 10 solutions, in terms of losses, are shown. Click OK to dismiss this window. The List of Results tab appears.
2.
3.
16-4
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You can now explore the performance and constructive results, as explained in Chapter 10, Performance Results and Chapter 11, Constructive Results.
Note:
This means that this design does not fulfill the specified inductance value. If the obtained inductance value is more than 1% different than the specified one, the core icon does not appear in the list. For example, if you select the first design from the List of Results tab, and then click the Constructive Results tab, you obtain the cross-section of the planar inductor, as shown below:
16-5
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16-6
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PExprt has been designed to work with toroidal designs using the same philosophy as concentric components. The goal for this chapter is to:
Repeat the design of the buck inductor, this time using a toroidal core.
Time:
17-1
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3.
To change the Spacing to reasonable values for a toroidal design, select Spacing, and enter 10 % in both the Intra-layer and Inter-layer fields.
To select appropriate core sizes for this particular toroidal design: 1. Click the Cores tab in the Libraries area, and expand the Ferroxcube_Design/Toroidal library.
17-2
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2.
Right-click to select TN19/11/10, TN19/11/15, and TN20/10/7. A "tool" icon appears in front of each selected core, as shown below:
To select appropriate core materials for a toroidal component (no air gap): 1. Click the Material tab in the Libraries area, and expand the Ferroxcube_Design library.
2. 3.
Right-click on the FERRITE type, and select Unselect All from the shortcut menu. The FERRITE label now appears in gray, indicating there is no core material selected. Click File/Save to save the project.
To start the design process for this toroidal component: 1. Click Calculations/Start Design Process. The Auto-Select feature is applied for the toroidal cores and the wires selection. A window appears, asking if you want to auto-select the cores and wires. Click Yes to have PExprt automatically select the cores and wires. The design process begins. When the design process has completed, a design report message appears, telling you how many valid designs have been obtained from the total number of designs analyzed. In this particular case, PExprt tells you it has obtained 467 valid results out of 494 analyzed designs. Since you specified Solution Selection on the Modeling Options tab, only the best 10 solutions, in terms of losses, are shown.
Toroidal Component Designs 17-3
2.
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3.
You can now explore the performance and constructive results, as explained in Chapter 10, Performance Results and Chapter 11, Constructive Results. For example, if you select the first design from the List of Results tab, and then click the Constructive Results tab, you obtain the top view of the toroidal inductor, as shown below:
17-4
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Index
Numerics
1D analytical model 12-4
A
alias 2-4 Analysis Mode 13-1 analytical-based model 15-3 analytical-based modeling 12-1 Ansoft SIMPLORER 15-1 Ansoft software, installing 1-v automatically select design elements 5-5 Auto-Select feature 5-5
Control Panel about 2-2 buttons 2-2 starting 2-2 creating project directory 2-4 projects 2-1, 2-6 criteria for Auto-Select 5-5 current density 10-9
D
defaults for Auto-Select 5-5 defining modeling language 12-3 Design Inputs tab 7-2, 7-3 design library role 5-2 selecting 5-2 selecting elements 5-3 Design Mode 13-1 design parameters 7-3 design process starting 9-2 designing magnetic components general procedure 1-3 designs generating 9-1 directory
Index-1
B
bobbin 7-4 buck inverter sample problem 1-4
C
classifying the list of results 10-2 component 11-3 constructive results parameters 11-3 Constructive Results tab 11-1
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alias 2-4 project 2-4 dragging stock library to design library 5-2
L
libraries stock 3-6 Libraries area 3-5 limit values 7-5 linking to PEmag 14-1 list of results settings 8-5 List of Results tab 9-4 losses 10-5
E
electrical simulators 15-1 Elements Information area 3-5 English units 3-9
F
FEA-based 2D model 14-3 flux density 10-9 fringing gap energy 7-5
M
margin tapes 7-5 Maxwell 3D installing 1-v Maxwell SPICE 3-6 metric units 3-9 model generating analytical model 15-3 model language defining SIMPLORER 15-2 modeling analytical 12-1 generating a 1D analytical model 12-4 modeling language 3-6 defining 12-3 Modeling Options tab 8-2, 8-3 modeling parameters 8-3 models FEA 14-3 modes in PExprt 13-1
G
gap 7-3 general procedure PExprt 1-3 generating designs 9-1 geometry 7-3 Graphical Information area 3-5 grayed-out (text and buttons) 2-7
I
incremental permeability 10-10 inductance 10-9 Input/Output Data area 3-4 Constructive Results tab 11-1 Design Inputs tab 7-2 List of Results tab 9-4 Modeling Options tab 8-2 Performance Results tab 10-1 Waveforms tab 6-2 installing Ansoft software 1-v introduction PExprt 1-1 invoking PEmag modeler 14-2
N
new project 2-6
O
objects drawing 3-1 opening projects 3-2 optimizing the number of turns for minimum losses 8-
Index-2
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4 Options/Preferences 3-6
R
results 9-1 results to expect 1-6 results, viewing 7-6, 14-7, 16-6, 17-4 role of design library 5-2
P
parameters constructive results 11-3 performance results 10-5 PEmag 14-1 generating a model 14-3 invoking modeler module 14-2 using PEmag models in PExprt 14-6 performance results parameters 10-5 Performance Results tab 10-1 permeability 7-3, 10-10 PExprt general procedure for designing magnetic components 1-3 results to expect 1-6 sample problem, buck inverter 1-4 starting 3-2 PExprt working window 3-4 planar magnetic components 16-1 Post Processor starting 7-6, 14-7, 16-6, 17-4 Power Electronics Expert (PExprt) introduction 1-1 preferences 3-6 modeling language 3-6 stock library settings 3-6 units 3-9 project add 2-4 creating 2-1, 2-6 directory 2-4 new 2-6 notes 2-7 opening 3-2 Project Manager starting 2-3 window 2-2 PSpice 3-6
S
sample problem buck inverter 1-4 selecting a design library 5-2 selecting elements from the design library 8-5 selecting library elements 5-3 SIMPLORER 3-6, 12-3, 15-1 using a PExprt model 15-4 solution results 9-1 solutions, generating 5-1 specifications for sample problem 1-4 starting Control Panel 2-2 PExprt 3-2 Post Processor 7-6, 14-7, 16-6, 17-4 Project Manager 2-3 starting the design process 9-2 stock libraries 3-6
T
temperature rise 10-9 toroidal component designs 17-1
U
units of measurement 3-9
V
ventilation type 7-3 viewing results 7-6, 14-7, 16-6, 17-4
Index-3
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W
Waveforms tab 6-2 winding DC losses 10-7 winding efficiency 7-4 winding losses calculation 8-3 winding setup 7-4 window Project Manager 2-2 window occupancy 10-8 working window 3-4
Index-4
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