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AN109
Push-Pull Converter Design Using a
CoreMaster E2000Q Core
By
Colonel Wm. T. McLyman
The single output push-pull converter is shown in Fig.1.
Vnom = 28 V
Vmin = 24 V
Vmax = 32 V
VO = 5 V
IO = 10 A
Center tapped
f=100 kHz
= 0.5 %
= 98 %
Bm = 0.1T
KU =0.4
Vd = 1 V
Dmax =0.5
Tr=25C
At this point, select a wire so that the relationship between the ac resistance and the dc resistance
is 1.
RAC
=1
RDC
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AN109
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The skin depth in cm is:
=
=
6.62
f
6.62
100,000
= 0.0209 [cm]
Wire AWG
#26
#27
#28
Bare Area
0.00128
0.001021
0.000804
Area Ins.
0.001603
0.001313
0.000105
cm
/
Bare/Ins.
0.798
0.778
0.765
1345
1687
2142
PO = 10 (5 + 1) = 60 [W]
Step No. 2. Calculate the total apparent power, Pt.
2
Pt = PO
+ 2
1.41
Pt = 60
+ 1.41 = 171 [W]
0.98
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Step No. 5. Select from the data sheet a E2000Q core comparable in core geometry, Kg
Core number
Manufacturer
Magnetic material
Magnetic path length, MPL
Core weight, Wtfe
Mean length turn, MLT
Iron area, Ac
Window area, Wa
Area product, Ap
Core geometry, Kg
Surface area, At
TEA0112Q
CMI
E 2000Q
5.11 cm
9.5 g
3.4 cm
0.24 cm2
0.866 cm2
0.208 cm4
0.00594 cm5
24.9 cm2
Step No. 6. Calculate the number of primary turns NP using Faradays Law.
VP ( MIN ) 104
Np =
f Ac B AC K f
12 104
= 25 [turns]
100,000 0.24 0.1 4.0
Step No. 7. Calculate the current density J using a window utilization, Ku = 0.4.
Pt 104
J=
f AP BAC Ku K f
NP =
171 104
= 514 [A/cm2 ]
100,000 0.208 0.1 0.4 4.0
Step No. 8. Calculate the input current, Iin.
P
I IN = O
VIN
60
I IN =
= 2.55 [A]
24 0.98
Step No. 9. Calculate the primary bare wire area, Awp(B)
I DMAX
Awp ( B ) = IN
J
2.55 0.707
Awp ( B ) =
= 0.00351 [cm2 ]
514
Step No. 10. Calculate the required number of primary Snp. Using the area of a #26 wire.
A
Snp = wp ( B )
# 26
0.00351
Snp =
= 2.74 use 3
0.00128
Step No. 11. Calculate the primary new /cm from the number 26AWG.
/ cm
new / cm =
Snp
J=
new / cm =
1345
= 448
3
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Step No. 12. Calculate the primary winding resistance, Rp.
6
RP = MLT N P
10
cm
RP = 3.4 25 448 10 6 = 0.0381 []
Step No. 13. Calculate the primary copper loss, PP.
PP = I Pr ms 2 RP
PP = 2.552 0.0381 = 0.247 [W]
Step No. 14. Calculate the number of secondary turns, NS.
N V
N S = P S 1 +
VPMIN 100
VS = VO + Vd
VS = 5 + 1 = 6 [V]
25 6 1.0
1 +
= 6.31 use 6 [turns]
24 100
Step No. 15. Calculate the secondary bare wire area, Aws.
I DMAX
Aws = O
J
10 0.707
Aws ( B ) =
= 0.0138 [cm 2 ]
514
Step No. 16. Calculate the required number of secondary strands, Sns.
Aws ( B )
Sns =
# 26
0.0138
Sns =
= 10.78 use 10
0.00128
Step No. 17. Calculate the secondary new mW per centimeter using number 26 AWG.
/ cm
( new) / cm =
NS S
1345
( new) / cm =
= 134.5
10
Step No. 18. Calculate the secondary resistance, Rs.
6
RS = MLT N S
10
cm
Rs = 3.4 6 134.5 10 6 = 0.0027 []
Step No. 19. Calculate the secondary copper loss, PS.
PS = I S 2 RS
NS =
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Step No. 21. Calculate the transformer regulation, .
P
= CU 100%
PO
0.521
=
100 = 0.868%
60
Step No. 22. Calculate the milliwatts per gram, mW/g.
2.1122
mW / g = 8.64 107 f 1.834 BAC
mW / g = 8.64 107 100,0001.834 0.12.1122 = 9.875
Step No. 23. Calculate the core loss, PFe.
PFe = ( mW / g ) Wtfe 103
PFe = 9.875 9.4 103 = 0.0928 [W]
Step No. 24. Calculate the total loss, P.
P = PCu + PFe
P = 0.521 + 0.0928 = 0.614 [W]
Step No. 25. Calculate the watt density, .
P
=
At
0.614
=
= 0.0247 [W/cm2 ]
24.9
Step No. 26. Calculate the temperature rise, Tr.
Tr = 450 0.826
Tr = 450 0.02470.826 = 21 [o C]
Step No. 27. Calculate the total window utilization KU.
KU = KuP + KuS
2 N S S N Aws
KuS =
W
2 6 10 0.00128
= 0.154
0.866
2 N P SnP AwP
KuP =
W
2 25 3 0.00128
KuP =
= 0.222
0.866
Ku = 0.222 + 0.154 = 0.376
Kus =
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BIBLIOGRAPHY
Colonel William T. McLyman, Transformer and Inductor Design Handbook, Second Edition,
Marcel Dekker Inc., New York, 1988.
Colonel William T. McLyman, Magnetic Core Selection for Transformers and Inductors, Second
Edition, Marcel Dekker Inc., 1997
Colonel William T. McLyman, Designing Magnetic Components for High Frequency, dc-dc
Converters, Kg Magnetics, Inc., 1993.
For information regarding the above Books and Companion
Software for Windows 95', 98' and NT, contact:
Kg Magnetics, Inc.
38 West Sierra Madre Blvd, Suite J
Sierra Madre, Ca. 91024
Phone: (626) 836-7233, FAX: (626) 836-7263
Web Page: www.kgmagnetics.com
Email: sheasso@pacbell.net
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