SC4: Practical Inductor DesignInstructor: Keith Williams, ConsultantThursday, May 15, 2014 8:30 am - 2:00 pmCourse Description:

II. Design Theory• Current and Flux• Flux and Voltage• Inductance• Permeability, Hysteresis, and SaturationIII. Types of Inductors• Linear Inductors• Swinging Chokes• AC Reactors• Air-Core Inductors

IV. Design Practice• Core Selection - Material• Core Selection - Size• Current and Flux Density• Turns and Air Gap(s) - DC Inductors• Turns and Air Gap(s) - AC Inductors• Three-Phase Inductors• Temperature Rise• Other Core MaterialsV. Other Considerations •• Stray Fields• Powdered Iron and Ferrite Cores: Thermal RunawayVI. Air-Core Coils

Short Courses

Instructor: Colonel Wm. T. McLyman, KG Magnetics, Inc.2-day, 12-hour courseMonday, May 12, 2014 8:30 am - 4:30 pmTuesday, May 13, 2014 8:30 am - 4:30 pm

SC1: Practical Power Magnetics Design Techniques

Course Description:The course covers a variety of basic topics including magnetic fundamentals and materials; dynamic B-H loop; permeability and the

presentation outlines, view web page at www.kgmagnetics.com and highlight “Presentation Outline”.

Who Should Attend:

course would provide managers, design engineers, project engineers, system engineers and even the novice the opportunity to explore in depth the state-of-the-art of practical magnetic design. Anyone involved in switch mode power conversion, power processing, and solid-state lighting would

Free copy of the complete TITAN Magnetics Design Program. Go to www.kgmagnetics.com to see all of what the Titan disk contains.

About the Author:

his thirty years at Jet Propulsion Laboratory (JPL) he worked on power conversion and as the magnetic specialist. He has worked on projects for NASA

Telescope, Seasat, SIR-C, Mars Global Surveyor, NSCAT, and the Deep Space Network.

He designed the Galileo signal rotary transformers used by the Command Data System (CDS), when the slip rings produced excessive noise on the 1-Mbit data bus. The performance of the signal rotary transformer exceeded all expectations. The rotary transformer on the Galileo Spacecraft lasted the life of the spacecraft, from 1989 to 2003 without a glitch.

He has designed the Quiet Converter with its low noise environment into programs, such as WF/PC-II, Articulated Fold, Mirror Actuators, (Hubbell Space Telescope), MISR (Earth Orbiting System), Raman, and Mars 05 ONC, CCD Camera.

He is the author of four popular textbooks, Magnetic Core Selection for Transformers and Inductors, Designing Magnetic Components for High-Frequency DC-DC Converters, High Reliability Magnetic Devices: Design and Fabrication, and just released in May, 2011 the Fourth Edition of Transformer and Inductor Design Handbook.

magnetic components. He is known as a recognized authority in magnetic design throughout the world.

SC3: EMI Fitler Design Seminar Instructor: Mr. Richard Ozenbaugh Wednesday, May 14, 2014 8:30 am - 2:00 pm

Course Description:This course covers a variety of basic topics including EMI components such as inductors, capacitors, arresters and EMI gaskets. The Inductor stores

ways to reduce this. tor value to ground.

is the advantages and disadvantages of going to a higher multiple of a topology - from a double π to a triple π? 3) What are virtual grounds and how do they help common

y and what happens

The above questions and other similar issues will be answered in detail. The goal of this course is to provide techniques for solutions.

Who Should Attend:f EMI Filter Design. This

course would provide engineering managers, electrical design engineers, project managers, system engineers and even the technicians the opportunity to explore EMI Filter Design in depth.

About the Author:Mr. Richard (OZ) Ozenbaugh has thirty year in the EMI arena and has written six articles in various technical magnetic magazines and one article for ITEM. He worked three plus years at Hopkins Engineering in Sylmar California and several years at RFI on Long Island, New York and consulted for EMI houses

ith Timothy Pullen at Rockwell Collins in Cedar Rapids, Iowa.

Starting with basic principles of electricity and magnetism, this course will develop a logical process to design inductors using a variety of core materials. The course will be useful to both the engineer new to magnetic component design and the experienced designer who wishes to sharpen his or her skills. Several design examples will be included in the course.

SC5: Short Course and Hands-on Design Workshop: Electromagnetic and Thermal Design of Synchronous Brushless PM MachinesInstructors: Mircea Popescu and David Staton, Motor Design, Ltd.,

Dan M. Ionel, Regal Beloit, Corp., and University of Wisconsin, Milwaukee Thursday, May 15, 2014 8:00 am – 5:00 pm

Brief Description:

teaching and interaction from three expert industrial and academic instructors having a combined experience of more than seventassumed that the course participants have at least working knowledge of electric machine theory; those requiring a refresher are encouraged to attend the free of charge tutorial organized during the EMCW show in Milwaukee on the afternoon of Wednesday, May 15 2014.

Lecturing and Q&A Modules:L1) Introduction – fundamentals of synchronous brushless PM machines and drives; main motor components; principles of operation

L2) Construction – state-of-the-art technologies; surface and interior PM motors; inner and outer rotors; magnets; electric steels; phases; concentrated/

average torque; cogging and torque ripple; radial forces; copper, core, and magnet losses; abnormalities and faultsL4) Thermal and coupled analysis – heat transfer mechanisms: conduction, convection, radiation; lumped thermal networks; numerical and CFD methods; duty cycles; advanced cooling systems; manufacturing uncertainties; sensitivity studies; multi-physics analysis.

Hands-on Design Moduleshe motor geometry;

implement an automatic or custom winding as a function of slot/pole ratio; select electric steel and magnet materials; estimate the main electromagnetic ses; multi-physics

questions from the instructors; advanced topics to be addressed include: core, magnet, and AC winding loss reduction techniques; torque ripple minimization methods: slots/pole optimum combinations, axial skew, airgap and magnet pole arc design; control strategies: maximum torque per amp

ity and optimization.

CEUs (PDH Equivalent)ts), which are

equivalent to 8 Professional Development Hours (PDH).

Notes:1) Included with the workshop registration fee is a 2-months license to the electromagnetic and thermal modules of the Motor-CAD and Motor-LAB software. Details on installation and activation will be provided in advance to the registered participants2) A break for lunch on your own will start at noon3) The class size is limited. Please register soon.

About the Instructors:Dr. Mircea Popescu is the Engineering Director of Motor Design, Ltd., a software and consultancy company headquartered in the Uthe US, and has more than thirty years of engineering experience. Earlier in his career, he was with Helsinki University of Technology (now Aalto University) in Finland and with the SPEED Lab at University of Glasgow. Dr. Popescu published more than one hundred papers and his publications have received three IEEE best paper awards. His consultancy contributions for industry are incorporated in many state-of-the-art products. Current major projects include electrical machines and drives for hybrid/electrical vehicles, and formula-e racing cars. Dr. Popescu is an IEEE Industry Application Society (IAS) Distinguished Lecturer for 2014 and 2015.

o following previouswork in the UK with the SPEED Lab at University of Glasgow and Control Techniques, which is part of Emerson Electric. Dr. Staton published more than

for many leading manufacturers worldwide, as listed on the Company website www.motor-design.com. The latest software from Motor Design, Ltd., is a unique template-driven program for coupled electromagnetic and thermal industrial design of electric motors and generators.

Dr. Dan M. Ionel, Chief Engineer with Regal Beloit Corp., and Visiting Professor at University of Wisconsin – Milwaukee, has moengineering experience. After completing postdoctoral work in the SPEED Lab at University of Glasgow, his industrial experience with Fortune 1000 and FTSE 100 Companies in the US and the UK includes electric machines and drives with power ratings between 0.002hp and 10,000hp. An IEEE Fellow, Dr. Ionel holds more than thirty patents and has published more than one hundred papers, including two winners of IEEE best paper awards. He is the General Chair of the IEEE Conference on Electric Machines and Drives, IEMDC-2017, to be held in Milwaukee, WI.

SC2: Polymer Chemistry for Engineers & TechnologistsInstructor: Dr. James V. Masi, JM Design ConsultantsTuesday, May 13, 2014 1:00 pm - 5:00 pm

1. Introduction, History, and Uses of Polymers

3. Polymer Chemistry4. Advantages and Disadvantages of Thermoplastics5. Advantages and Disadvantages of Thermosets6. Polymerization reactions7. Time-Temperature-Transformation Diagrams8. Cure reactions and curing agents9. Cross-linking and chain polymerization10. Types of polymers11. Mechanical Properties12. Electrical Properties13. Chemical Properties14. Elastomeric materials

15. Polymer morphology and processing16. Extrusion Process17. Injection Molding process18. Blow Molding19. Thermoforming20. Rotational Molding process21. Casting Process22. Foaming Process23. Compression and Transfer Molding24. Polymeric Composite Materials25. Radiation Processing26. Designing with plastics27. Environmental aspects of polymers28. Testing and Operations

Course Description:The course will be presented by means of demonstration, PowerPoint slides, experiment (real and virtual), and parts display. Each participant will

various polymers

About the author: in Materials Science from the

University of Delaware. He has over 45 years experience in industry and academia and has worked and researched in solid state devices, liquid crystals, corrosion, semiconductors, luminescence, energy devices, electromagnetics, dental materials, and other areas of materials science. He joined Western New England College in 1980 and is presently professor emeritus of Electrical Engineering and Bioengineering. He was Exec. Dir of The Northeast Center for Telecom. Technologies (NSF Center of Excellence) from 1997-2001. He is presently a research professor at the University of Southern Maine. He is retired and is a consultant in JM Design consultants. He holds over 60 patents, has authored over 140 articles and papers, and has authored 3 books and 3 videotapes. He is a member of the IEEE, ASME, ASM, SPIE, ECS, AVS, AAPT, and is a fellow of the AIMBE.

Course Description: 

Introduction to coil manufacturing is an intense one day course.  Coil types such as solenoid, stator, 

transformer and inductor will be reviewed.  This full day course will cover; materials such as wire, bobbins, 

encapsulants, insulation and cores; winding techniques; assembly techniques; encapsulation techniques. 

Who should attend: 

Anyone new to the coil winding industry, this includes designers, managers, purchasing, document 

control,quality and of course operators.   

About the author: 

Robert Sanchez is a graduate of Sandia National Laboratories’ Engineering and Science Training Program. Robert worked in the magnetics department at Sandia for 36 years. He was the Product Realization Team (PRT) leader for magnetics until his retirement in December of 2011. He was responsible for manufacturing oversight of Sandia designed magnetics at three commercial vendors and before that at two of DOE’s large production facilities. Robert has been the magnetics technical project leader for numerous Sandia weapon system projects including, perfect lay coil winding, high reliable chip inductors, miniature HV flyback transformers, elimination of encapsulation voids in magnetics, and eliminating audible noise in sensitive transformer applications. Upon his retirement from Sandia Robert started his own consulting firm called Hi-Rel Solutions with consultation on magnetic component design and manufacturing, specializing in encapsulation/impregnation of magnetic components. Robert has authored and presented over 20 publications related to magnetics. Robert is a member of the Electrical Manufacturing Coil Winding Association (EMCWA) where he serves on the Board of Directors and is, in addition, the co-chair of the Technical Committee. He also served on the Industry Action Council for The School of Engineering at Western New England University. Robert holds two US patents, the first on “Novel Magnetic Materials for Low Loss Devices at High Frequencies” and the second “High Frequency Transformers and high Q-Factor Inductors Formed Using Epoxy Based Polymers”. Robert has over 38 years’ experience in magnetics.

SC6: INTRODUCTION TO COIL WINDINGInstructor: Robert Sanchez, Hi-Rel SolutionsWednesday, May 14, 2014 8:30 am - 2:00 pm