Transformer Design Tool
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This tool helps a power supply engineer to select the right isolated DC-DC topology based on the specifications. Depending on the topology chosen, the calculator also recommends the right IC for the design.
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Ansys VeloceRF allows you to synthesize devices with tight packing of multiple devices and lines for an optimized silicon floorplan. Analysis of the coupling among any number of inductive devices before detailed layout will reduce design size and reduce or eliminate guard rings.
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Ansys VeloceRF synthesizes and analyzes mm-wave spiral devices and T-lines in just a few minutes. It generates DRC/DFM clean devices - including fill - down to 3nm. The devices are modeled by passive, causal S-parameters and highly compact RLCk netlist models and can be delivered as PCells/PyCells for maximum geometric flexibility. In-context optimization allows significant die size reductions through tight floor plan packing of multiple devices and lines and the reduction or elimination of guard rings. It supports high frequency with a pre-defined library of device building blocks and supports coupling among any number of inductive devices.
Ansys VeloceRF calculates coupling among any number of inductors to better optimize silicon real estate. With VeloceRF, you can tighten or eliminate guard rings and also optimize the silicon floorplan.
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Ansys VeloceRF currently supports over 200 unique foundry technologies and works with any process (CMOS, BiCMOS, GaAs, SOS, SOI) from semiconductor foundries, including TSMC, UMC, Global Foundries, TowerJazz, Samsung, and others. VeloceRF supports all process nodes down to 3nm. It integrates with leading EDA platforms and VeloceRF models can be combined with parasitic extracted netlists.
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Now, I am trying to simulate your 2kW (PMP8740) dc-dc converter circuit in TINA-TI . I am using PMP8740 dc-dc converter schematic circuit identically except for Voltage and current loop Op-amps . I adjusted the output of dc dc converter 32V 1920W at full load because in the PMP8740 UCC28950 Excel design tool " output is 32V and 1920W. My purpose is determine T4 transformers technical specs and understand the circuit.
Nevertheless, the delay times are, also for my prototype, starting points (and I didnt change them finally). After you build your own, you may want to fine tune these parameters in order to optimize the efficiency. So, you can use the value I employed in my PMP8740, as starting point, without problems.
1) The calculation of cross section area is correct. In theory its equivalent to use a copper foil 12.56mm-width x 0.1mm-thickness, instead of 160 wires with 0.1mm diameter. The difference is that the interwinding capacitance is pretty much higher with copper foil, leading to multi-resonance frequencies. So, maybe it doesnt affect the performance, but I would test both solutions, even just winding prototypes.
2) As far as I rememeber (I dont have this data, because the transformer was already built) the primary side wire was a single LITZ wire, while on secondary side it was a pack of several LITZ twisted together, but I dont know the exact amount of wires.
3) As for point 1, you can use copper foil instead of LITZ. In this case it makes more sense and I would suggest to do that, because we have only a limited amount of turns, which reduces the total amount of interwinding capacitance.
Can you also share the technical details of T4?
I would like to build a 240Vdc to 24Vdc battery charger, using a planar transformer. So a different ratio but I really would like to know what you have used for your 400Vdc to 24V converter
One single core has external diameter = 40mm and thickness 15mm. By putting these two cores in parallel, the thickness will be 30mm, and the Al value double (The total inductance is 210uH).
I wounded 35 turns of single enamelled copper wire, with a diameter of 1.6mm.
I added isolation tape before winding; in theory is not necessary, because the core is already coated, but it increases the isolation, and its easier to slide the turns in and out.
For Pfc inductor, The total inductance is 210uH and number of turns=35 and the total Al value is 171.43 nH /N^2 . One core has 85.714 nH / N^2 Al value. I didn't find same NKL CM400125 D0522-00 part number core. I find micrometals powder core Al= 80nH /N^2 and u=60. When I used 2 core from micrometals, the total Al is 160nH/N^2 and to get 210uH inductance , I should wound 36 turns (207.3uH total inductance approx). I attached datasheet of the micrometals core. Is this core suitable for my PFC inductor ?
This transformer has lower magnetizing inductance, compared to the one in the BOM, but I verified that the magnetizing current isnt too high and is manageable by the gate drivers. Also the volt per usec product is ok, so no saturation will occur.
I have a question about gate drive transformers .In the datasheet there is also P0584ANL part number transformer. Do you suggest this transformer instead of P0584NL ? and Are there important differences between P0584NL and P0584ANL transformers?
My another question about PFC Heat sinks. In PFC schematic HS1 for bridge rectifier and part number SK 481-50 and length of this heat sink 50mm. It is Ok. HS2 and HS3 has SK 481-100 part number and length of this heat sinks are 100mm . If HS2 and HS3 are used together , total heat sink length should be 200mm. But in the PFC layout total length is 100mm. Are HS2 and HS3 part number correct ? and Why do you use two seperate heat sink to obtain 100mm lengt.? Could one heat sink to be enough?
The difference between P0584NL abd P0584ANL is the the version with "A" is 4250Vrms rated, while the non-"A" version is 3000Vrms. So depends on the specification about the isolation voltage in your application you may want to use one of them. From my perspective, since both are reinforced, you may want to employ the one at 3000Vrms, because it has lower leakage inductance.
AC voltage sensing transformer: I am not sure we need here this exact part number because I used it as current transformer and not voltage transformer (like it is). As you can see from the schematic, the load of this transformer is a "virtual" short circuit (done with an op-amp) therefore the magnetizing current doesn not play any role. This way you should get the same result by using a "normal" 50/60 Hz small transformer, or even better an audio transformer, like the one at the link below:
For AC voltage sensing transformer : In audio transformer you suggested me , turns ratio Np/Ns 1:1 and 2:1. Which one can I use for same voltage sensing circuit in the schematic. 1:1 or 2:1. In PA3000NL datasheet turns ratio 1:1.
In Pfc schematic one pin of bridge rectifier heat sink (HS1) connected to the GND-P and one pin of HS3 (for boost diodes and mosfets ) connected to 1000pF capacitor. Are these connections important ?
Also , in pfc schematic there is a BAS21 (D100) diode connected to the pin 3 of ucc28180 ic in rev. E schematic but in PFC pcb layout I didn't find D100 diode. Why did you add this diode in revision E schematic.? and Where can I place this diode in pcb layout ?
The reason why I prefer to add a small capacitor in series is: first, a small capacitor is a short circuit for the high frequency band of the noise (typically due to high dV/dT), therefore its like its shunting the most of the noise to grund. Second, if the capacitor fails, and shorts, there is still the isolation pad (Sil-Pad) between the FET and the heatsink. In case the Sil-Pad fails and shorts the FET drain to the heatsink, we have still the small capacitor isolating the heatsink to ground.
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