CSC金属磁粉芯大功率产品培训资料

78%
300
CSC
2011
82%
180
81%
260
High Flux
2012 Plan
84%
160
82%
250
High Flux
78%
400
74%
340
Market/其它
MPP
60%
150
51%
210
※Main Application : High Efficiency Server Power, Solar Inverter Telecom Power, High Power Personal Computer
Core Design
6. Material Selection/材料的選用
•When you design and select the right material, core cost is the most important factor but there need many other consideration 設計時除考量成本為主外還要考量到實際應用需求
Block
E
EER
EQ
Cylinder
Round Block
U
Materials Perm.
26μ
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MegaFlux 40μ
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60μ
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26μ
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Sendust 40μ
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60μ
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26μ
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HighFlux 40μ
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60μ
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Core Design
5. Core Design Required Information/設計需求資料 (1) Inductance[μH or mH], Current [A]/電感量及電流
For Calculating LI2, Core Loss, Wire Size, Copper Loss 用來計算LI2,磁損,線徑,銅損 (2) Current Density (A/cm2 or A/mm2)/電流密度 For Calculating Wire Size, Copper Loss 用來計算線徑,銅損
Poor
Lowest
20
High
Better Lowest
15
Low
Better Medium
3-5
Lowest Poor
Lowest
Better Good Better Poor Good Good Poor
500 500 700 770 740 399 100~300
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Core Design
8. Winding/繞線工藝
(1) Winding Layer/層數 • Single Layer Winding : Low Winding Capacitance à Good High Freq. Response Winding is Easy but Need more Large Size Core for Same L • Multi Layer Winding : Small Size Core for Same L but Winding is Hard High Winding Capacitance à Need Special Winding Method
Core Design
9. Temperature Rising
(3) Core Loss/磁損
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1. Toroidal Core
7. Inductance
• After selecting material, core size and permeability should be selected 選材質,尺寸,磁導率,
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Mold Size
4
10
6
6
6
5
7
Design Tool
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ER
Ellipse
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5
5
△
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2. Special Shape Powder Core
1. Big Toroidal Core
(1) Features/特性
• Out Diameter 100, 132, 165mm/外徑 • MPP, High Flux, Sendust, Mega Flux/材質 • Electrical Characteristics are Same with Small toroid cores /特性同我們常見的SIZE
(3) Ripple Rate (%)/紋波範圍 For Calculating ΔI, Core Loss 為計算增量電流,及磁損
(4) Switching Frequency (kHz)/開關頻率 For Calculating Core Loss 用來計算磁損
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SENDUST
(Fe-Si-Al)
Mega Flux
(Fe-Si)
Iron
(Fe)
Strip/帶材 Fe-Si/硅鋼
Amorphous/非晶 Permalloy/破莫合金
1. Toroidal Core/環形
2. What is Powder Core ? /磁粉芯介紹
Powder Cores are distributed air gap cores made from ferrous alloy powders for low losses at elevated frequencies. Small air gaps distributed evenly throughout the cores increase the amount of DC that can be passed through the winding before core saturation occurs.
1. Toroidal Core
5. Electrical Characteristics of High Flux Material /CH材料電氣特性
2010
60μ
DCB% @100 Oe
Core Loss @50kHz,1000G
79%
240
125μ
DCB% @50 Oe
Core Loss @50kHz,1000G
MPP Cores
Ellipse CORE
Sendust Cores
Fe-Si-Al alloy
Black Color Low Core Loss Moderate Price Perm 26, 60, 75, 90, 125u
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Mega Flux Cores
EE CORE
Materials/材料
Perm./磁導率 (I)
Bs/飽合 磁感應 強度
(kG)
Core Loss/磁損
DC Bias /加載電
流
Relative Cost/成本
Temp. Curie Temp
Stability/溫 [℃]/居里溫
度特性
度
MPP
26-200
7
ห้องสมุดไป่ตู้
Lower Better
High
Best
EQ CORE
EER CORE
High Flux Cores
BLOCK CORE
Ni-Fe-Mo alloy
Gray Color Lowest Core Loss Excellent Temperature Stabiliy Perm 26, 60, 125, 147, 160, 173, 200u
磁粉
渦流
絕緣層&GAP
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3. Manufacturing process/生產流程 3. Manufacturing process/生產流程
制粉
絕緣處理
壓制
燒制
Material/材料
Composition/合金成份
High Flux : CH Ni + Fe Alloy/鎳鐵合金
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Core Design 8. Winding (3) Winding Method vs Impedance/繞線方法與阻抗
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Core Design 9. Temperature Rising/溫升
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Sendust : CS
Fe + Si +Al Alloy/鐵硅鋁合金
Mega Flux : CK Fe + Si Alloy/鐵硅
MPP : CM
Ni + Fe + Mo Alloy /鐵鎳鉬
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完成
性能測試
1. Toroidal Core
4. Material Comparison /材料比對表
(2) Application/應用
-CSC-
1. Toroidal Core/環形
1. Soft Magnetic Materials/軟磁材料
Soft Magnetic Materials Ferrite/鐵氧體
Metals/金屬
Powder/粉末
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MPP
(Ni-Fe-Mo)
High Flux
(Ni-Fe)
Soft Magnetic Powder Core 軟磁粉芯
Changsung Corp.
1. Toroidal Core /環形 2. Special Shape Powder Core/特殊形裝CORE 3. Ellipse Core Design/EL CORE設計 4. Q & A
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Core Design
7. Inductance/電感
(2) Height Change & Stack/高度變化及堆疊 • Energy Storage Capacity : LI2 [L=Inductance(mH), I=Current(A)]/功率容量 • Increase Energy Storage Capacity with same OD, ID size à Height Increase or Stacking 增加功率在相同的OD.ID的情況下,可通過增加高度及疊加方式增加
450
High Flux
Sendust
Mega Flux
Iron Fe-Si Strip
(Gap) Amorphous
(Gap) Ferrite (Gap)
26-160 26-125 26-90 10-100
15
Low
Best
Medium
10
Low
Good
Low
16
Medium Best
Low
10
High
Fe-Si alloy
Dark Brown Color Excellent DC Bias Large Energy Storage Capability Moderate Price Perm 26, 40, 50, 60, 75, 90u
2. Special Shape Powder Core
Part No. CH330060 CH330060E14 CH330060E18
CH330060 2Stack
B.F HT 10.67mm 14.0mm 18.0mm
10.67mm X2
AL Value 61mH 80mH 103mH
61 x 2 =122mH
Storage Capacity 25 32 42 50
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Core Design
8. Winding
(2) Split Winding/分開繞線 • Purpose : Minimize Stray Capacitance &Good High Freq. Response/高頻響應 • Two Layer Winding & Two Split Winding, Three Layer Winding &Three Split Winding
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2. Special Shape Powder Core
Ni-Fe alloy
Khaki Color Lower Core Loss,Excellent DC Bias
Large Energy Storage Capability Perm 26, 60, 125, 147, 160u
6. Core Selection Chart (Toroidal) /選擇曲線
• Energy Storage Capacity : LI2 [L=Inductance(mH), I=Current(A)]
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1. Toroidal Core
7. Inductor Design Tool/電感設計工具