speeding up transformer design through latest web tool 29/nov./2007 1 1 speeding up transformer...

Speeding up transformer design through latest Web tool 29/Nov./2007

www.powerEsim.com 11

Speeding up transformer design through latest Web tool



The Web tool . . . The Web tool . . .

• It’s on-line

• It’s for everyone

• Worldwide access

• 100% server side simulation

• It’s FREE !!



Free accounts from sponsorsFree accounts from sponsors

• Some sponsors provide a full features PowerEsim for public user.



Your private free account Your private free account

• User can apply for a 7 days private free full features account by email address.



It’s highly accurateIt’s highly accurateI/P Votlage Vs Efficiency %

0.0010.0020.0030.0040.0050.0060.0070.0080.0090.00

100.00

300 350 405

150W flybackInput Votlage Vdc

Input Votlage Vs Efficiency %

0.0010.0020.0030.0040.0050.0060.0070.0080.0090.00

100.00

85 110 230 265

160W PFC Input Voltage Vac



No expert knowledge neededNo expert knowledge needed

• Find MOSFET

• Find Diode

• Find Capacitor

• Find Core

• Find Wire

Rds*Crss

Vf*trrm

CV

k1, k2, k3

Current density

PowerEsim Traditional Design

• No equations needed!

• Simple pick and place components

• Or build real Xformer in virtual space



PowerEsim vs Traditional DesignPowerEsim vs Traditional Design

result oriented adaptive iteration

instead of

skill of knowledge application

PowerEsim turn design into



Designing a power supply - Ask our expertDesigning a power supply - Ask our expert

• Enter the input & output specification

• Chose an application

• Click “Recommend Design”



How our expert inside the server workHow our expert inside the server work

Specification Search for closest reference design

Search for best topologies

• Fuzzy logic is used to rank the topologies or reference design according to user’s requirements



Chose a PWM controller circuitChose a PWM controller circuit

• Double click the PWM block• Select the PWM controller• Another PWM circuit will appear



Preliminary design will be initializedPreliminary design will be initialized

• Preliminary design of real components will be initialized within a few seconds

• A virtual power supply is on the your bench



Now click T1 and go to Magnetic BuilderNow click T1 and go to Magnetic Builder



dvHI

uL

k

ok

2

H

Background Background - - What else we consider for a transformerWhat else we consider for a transformer

Leakage inductanceLeakage inductance

coscosh

sinsinh12 2

mPd

m=2

Proximity effectProximity effect

meterfu

Do

skin

Skin effectSkin effect

skinD

d

2

wire

wirewire dlBf

Pd

42

Fringing flux Fringing flux

22

321

Bfd

B

c

B

b

B

af

VolPd

kkk

Core lossesCore losses



Magnetic Builder Magnetic Builder - - Build a single transformer aloneBuild a single transformer alone

• User can build a single sand alone transformer by pressing the button “Magnetic Builder”



Design a single Xformer – Where it apply?Design a single Xformer – Where it apply?

• Choose the application of the magnetic component, e.g. it is a “Flyback Xformer” or “Input Choke”



Design a single Xformer – Design a single Xformer – Operating conditions?Operating conditions?

• Enter the simple operating condition of the application, e.g. the operating condition of the “Flyback converter”

• Press “Recommend Design,” a preliminary Xformer with core, wire, tape and winding sequence, will be recommended.



Design a single Xformer – “Design a single Xformer – “Recommended DesignRecommended Design””

• A preliminary transformer of real construction is ready to be edit and refine.

• This page is a simplified version of the Magnetic Builder.

• Excellent for quick design purpose.



Design a single Xformer – Design a single Xformer – Full version Magnetic BuilderFull version Magnetic Builder

• Click the “Advanced” button will go to the full version Magnetic Builder and do whatever you like.



First thing to design a XformerFirst thing to design a Xformer

• First thing to do - Select the varnish and UL insulation system first, of course.



Any real core you likeAny real core you like

• Chose the range of Ae

• Select Core shape

• Select Manufacturer



Instant preview winding when thing changeInstant preview winding when thing change

• Click the “preview winding”

• Corresponding winding cross section will be shown

• Supported on Core, N and Wire.



Seeking for the best LmSeeking for the best Lm

• Click the “Inductance” button

• Enter the range of inductance

• Highlight each in the list, select according to total loss and stress.



Find the best number of turnFind the best number of turn

• Click the “Number of turn” button

• Enter the range of turn

• Highlight each in the list, select according to total loss and stress.



No. of turn is not just an abstract number !No. of turn is not just an abstract number !

• Click the “Preview Winding” button

• Observe how winding structure change with number of turn.



Add more copperAdd more copper

• Click the “Change Wire” button

• Click the “No. of Parallel Wire”

• Add more parallel wire as you like.



Copper foil can be usedCopper foil can be used

• Click the “Use copper foil” button

• Enter the copper foil size



Faraday shield can be addedFaraday shield can be added• Click the “Add Pri Wdg” or “Add Sec Wdg” button

• Click the check box “Faraday Shield”

• Click the combo box W”x” to arrange for the layer of the Faraday shield

• You may go to “Winding Construction” page to further arrange for the shield.



Arrange each winding layer you likeArrange each winding layer you like



The dot of a windingThe dot of a winding

• User can define whether the winding is started at dot sign or not



Where to startWhere to start

• User can define whether the winding is started at upper end or lower end of the winding layer



How to wind a windingHow to wind a winding

• User can define the location of a winding at the center, lower part or upper part of the winding layer. Distribute the winding all over the layer is also possible.



Layer to layer winding methodLayer to layer winding method

• A winding may occupy more than 1 layer. Choose “Tight” will ensure wires to full up all space in it’s layer before go to the next layer. Choose “Shared” will resulting in even distribution on each layers



Inner tape between each layerInner tape between each layer

• Inner tape can be placed between each layer of Multi-layers winding.



Customize different bobbins typeCustomize different bobbins type

• Thickness of each wall and the type of split bobbin can be defined in “Bobbin Setting”.



You can make a transformer like this . .You can make a transformer like this . .

• You can change the number of wire used

• You can change the size of the wire

• You can control how you place the wire

• You can use copper foil to replace magnet wire

• You can split the bobbin

• You can add Faraday shield

• You can do anything you like . . . .



Transformer drawing will be followedTransformer drawing will be followed

• Transformer drawing will be automatically generated by pressing the “Generate Drawing” button.

• Details testing methods, P/N, material can be edit before printing.



Thermal – knowing Temp. at day 1Thermal – knowing Temp. at day 1

• May be the fastest and easiest thermal simulation tool for power supply. 5 s for a simulation only!!



DVT – check the stressesDVT – check the stresses

• DVT Report check every components stress and also circuit design constraint.



MTBF – how long it lastMTBF – how long it last



Use thermal result check boxUse thermal result check box

• Once this check box is clicked, all simulation, e.g. DVT, MTBF, etc, will be base on junction Temp. from thermal simulation result, otherwise default value will be used



Loop Analysis– how stable the systemLoop Analysis– how stable the system

• Gain and phase margin will be immediately known with after any change or circuit component



Loop Analysis– transient loadingLoop Analysis– transient loading

• Define step loading waveform and corresponding output transient loading response will be shown



Harmonic – Harmonic – knowing input current harmonics contentknowing input current harmonics content

• All input current parameters, e.g. PF, THD, harmonic content can be seen



Waveform – Waveform – the least important toolsthe least important tools

• Critical component’s waveform will be illustrated



BOM Builder – BOM Builder – BOM is always ready to print outBOM is always ready to print out

• BOM is always ready to print and will be updated automatically. It save a lot of preparing document time for engineer.



Report Builder – Report Builder – Generate all document with a clickGenerate all document with a click

• Simple a click - All result from analysis or tools can be exported to Excel file for engineering documentation.



Download – Download – a lot of document is ready to downloada lot of document is ready to download

• A lot of document and publication are ready to download. It is helpful to become a PowerEsim expert.



We believe . . .We believe . . .

speeding up transformer design through latest web tool 29/nov./2007 1 1 speeding up transformer...

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