Passive Components Blog
No Result
View All Result
  • Home
  • NewsFilter
    • All
    • Aerospace & Defence
    • Antenna
    • Applications
    • Automotive
    • Capacitors
    • Circuit Protection Devices
    • electro-mechanical news
    • Filters
    • Fuses
    • Inductors
    • Industrial
    • Integrated Passives
    • inter-connect news
    • Market & Supply Chain
    • Market Insights
    • Medical
    • Modelling and Simulation
    • New Materials & Supply
    • New Technologies
    • Non-linear Passives
    • Oscillators
    • Passive Sensors News
    • Resistors
    • RF & Microwave
    • Telecommunication
    • Weekly Digest

    Smolteks CNF MIM Capacitor Break 1 µF/mm²

    Samsung Electro-Mechanics Releases 0201 X7T 1uF 6.3V MLCC for ADAS Applications

    Murata Announces 0402 Automotive Chip Ferrite Beads for V2X

    2025 Thick and Thin Film Resistor Networks Environment Overview

    Role of High-Q Ceramic Filters to Overcome GNSS Jamming

    Optimization of IoT for GEO NB-NTN Hybrid Connectivity

    TDK Releases Automotive Power-Over-Coax Inductor for Filters

    Advanced Conversion Announces Mass Production of 200C Film Capacitors

    VinaTech Supercapacitors: Enhancing Smart Meter Reliability and Efficiency

    Trending Tags

    • Ripple Current
    • RF
    • Leakage Current
    • Tantalum vs Ceramic
    • Snubber
    • Low ESR
    • Feedthrough
    • Derating
    • Dielectric Constant
    • New Products
    • Market Reports
  • VideoFilter
    • All
    • Antenna videos
    • Capacitor videos
    • Circuit Protection Video
    • Filter videos
    • Fuse videos
    • Inductor videos
    • Inter-Connect Video
    • Non-linear passives videos
    • Oscillator videos
    • Passive sensors videos
    • Resistor videos

    Understanding Switched Capacitor Converters

    Coupled Inductors Circuit Model and Examples of its Applications

    Inductor Resonances and its Impact to EMI

    Highly Reliable Flex Rigid PCBs, Würth Elektronik Webinar

    Causes of Oscillations in Flyback Converters

    How to design a 60W Flyback Transformer

    Modeling and Simulation of Leakage Inductance

    Power Inductor Considerations for AI High Power Computing – Vishay Video

    Coupled Inductors in Multiphase Boost Converters

    Trending Tags

    • Capacitors explained
    • Inductors explained
    • Resistors explained
    • Filters explained
    • Application Video Guidelines
    • EMC
    • New Products
    • Ripple Current
    • Simulation
    • Tantalum vs Ceramic
  • Knowledge Blog
  • Suppliers
    • Who is Who
  • Events
  • Home
  • NewsFilter
    • All
    • Aerospace & Defence
    • Antenna
    • Applications
    • Automotive
    • Capacitors
    • Circuit Protection Devices
    • electro-mechanical news
    • Filters
    • Fuses
    • Inductors
    • Industrial
    • Integrated Passives
    • inter-connect news
    • Market & Supply Chain
    • Market Insights
    • Medical
    • Modelling and Simulation
    • New Materials & Supply
    • New Technologies
    • Non-linear Passives
    • Oscillators
    • Passive Sensors News
    • Resistors
    • RF & Microwave
    • Telecommunication
    • Weekly Digest

    Smolteks CNF MIM Capacitor Break 1 µF/mm²

    Samsung Electro-Mechanics Releases 0201 X7T 1uF 6.3V MLCC for ADAS Applications

    Murata Announces 0402 Automotive Chip Ferrite Beads for V2X

    2025 Thick and Thin Film Resistor Networks Environment Overview

    Role of High-Q Ceramic Filters to Overcome GNSS Jamming

    Optimization of IoT for GEO NB-NTN Hybrid Connectivity

    TDK Releases Automotive Power-Over-Coax Inductor for Filters

    Advanced Conversion Announces Mass Production of 200C Film Capacitors

    VinaTech Supercapacitors: Enhancing Smart Meter Reliability and Efficiency

    Trending Tags

    • Ripple Current
    • RF
    • Leakage Current
    • Tantalum vs Ceramic
    • Snubber
    • Low ESR
    • Feedthrough
    • Derating
    • Dielectric Constant
    • New Products
    • Market Reports
  • VideoFilter
    • All
    • Antenna videos
    • Capacitor videos
    • Circuit Protection Video
    • Filter videos
    • Fuse videos
    • Inductor videos
    • Inter-Connect Video
    • Non-linear passives videos
    • Oscillator videos
    • Passive sensors videos
    • Resistor videos

    Understanding Switched Capacitor Converters

    Coupled Inductors Circuit Model and Examples of its Applications

    Inductor Resonances and its Impact to EMI

    Highly Reliable Flex Rigid PCBs, Würth Elektronik Webinar

    Causes of Oscillations in Flyback Converters

    How to design a 60W Flyback Transformer

    Modeling and Simulation of Leakage Inductance

    Power Inductor Considerations for AI High Power Computing – Vishay Video

    Coupled Inductors in Multiphase Boost Converters

    Trending Tags

    • Capacitors explained
    • Inductors explained
    • Resistors explained
    • Filters explained
    • Application Video Guidelines
    • EMC
    • New Products
    • Ripple Current
    • Simulation
    • Tantalum vs Ceramic
  • Knowledge Blog
  • Suppliers
    • Who is Who
  • Events
No Result
View All Result
Passive Components Blog
No Result
View All Result

Custom Magnetic Design Process Flow

23.1.2024
Reading Time: 5 mins read
A A

This article is based on newsletter blog written by Sotiris Zorbas, MSc Power Εlectronics Εngineer of Frenetic that explore the basic aspects of a custom magnetic design process flow that an engineer should possess before starting a custom design inquiry.  

Basic Specs to Start with

In order to make custom magnetic samples and move to production, there are certain topics that needs to be clarified, such as:

RelatedPosts

How to design a 60W Flyback Transformer

How to Design LLC Transformer

Leakage Inductance Model; Frenetic Webinar Recording

  • Topology of the Inductor/Transformer operation.
  • Input and output voltages and currents of the power topology.
  • Frequency range.
  • Required insulation for the design.
  • Cooling options for the Converter.
  • Mass production requirements.

Then it’s time to perform spice simulations, what we look for at the beginning is the following:

Key Specification Parameters

Depending on the topology, the primary inductance (L, or Lp) is the first important spec needed to figure out.

For the Inductor, that would be the measured inductance across the terminals, while for the Transformer the primary inductance with the secondaries open. Measurements of inductance should be performed at least on the operating frequency range of the Magnetic part, as inductances vary with frequency!

For Transformers, the turns ratio n of the primary/secondary is also an indispensable parameter.

Depending on the topology and control options, both L and n need to be calculated. Without these specs, you can go no further. It’s common for uncertainty to surround these parameters, since the designer often needs to dive into equations to find a suitable range of values. Usually, the story is quite simple for Inductors, but not so much for Transformers!

Let’s pick some examples!

Figure 1 – A PSFB CT Converter

First example:

A client has a PSFB custom transformer and specifies 4mH of primary inductance. That much inductance is forcing the design into a high number of turns, thus increasing winding losses.

The question would be: Why does he need 4mH of inductance? Is he choosing to operate the PSFB Converter with peak current mode control scheme? The solution in this case is to double check the minimum inductance needed to safely operate in current mode control in this case and have a chat about it.

Second example: what should be the turns ratio in a PSFB?  

With the fair assumption that a maximum effective duty cycle of 70% is selected, given the highest/lowest voltages on the output/input respectively, we can calculate a turn ratio. Now, if the client does not have a clue of the effective duty cycle parameter, then we can ask for more info on his system to double check if this is the case.

Insulation

Do we need functional, basic, or reinforced isolation for the transformer design?

Don’t worry about the details. If that’s a new concept for you, we can propose appropriate insulation to meet certain standards for your product. The point with insulation is not only to pass the standards, but also to ensure the safety of the end-product user.

Cooling and Space

We are building a Magnetic part, let’s assume a Transformer. Typical efficiencies range vary from 98.4% to 99.7%. Although Magnetics are extremely efficient components by nature, there are losses that are then translated into heat, and we need to account for that.

Depending on the power level of the Converter, heat dissipation will result in a temperature rise. The usual specification is to keep temperature below a certain point under worst ambient temperature conditions. To achieve this, we need to cool the Magnetic somehow.

3 options for cooling are:

  • Natural convection cooled design.
  • Forced air cooling.
  • Potting and plate cooling

The Transformer temperature models we have developed will point us in the right direction once a design has been simulated and its power losses calculated. We need to keep in mind that the maximum dimensions of the Magnetic component will heavily influence the design options thus power losses, temperature rise and finally cooling method.

Samples and Production

When a salesperson inquiry about mass production volume and timelines, their intent is clear: ensure feasibility within specified timelines and cost structures that align with both the client’s and Frenetic’s objectives. No mysteries here…

But when our engineers ask you these very questions, why is that? The difference between creating a functional sample meeting specifications and designing a product suitable for large-scale manufacturing becomes apparent. That’s just reality. When we start with mass production as a goal with certain price tags, the designs are going to be different, even at the initial sampling stage.

Related

Source: Frenetic

Recent Posts

Murata Announces 0402 Automotive Chip Ferrite Beads for V2X

19.6.2025
5

TDK Releases Automotive Power-Over-Coax Inductor for Filters

18.6.2025
6

Bourns Introduces New Automotive Grade BMS Signal Transformer

17.6.2025
6

YAGEO Releases High Isolation Transformer for 1500VDC Applications

12.6.2025
23

Exxelia to Present Smart Integrated Magnetics and MML Film Capacitors at SIAE25 

6.6.2025
35

YAGEO Unveils PulseChip LAN Transformer

6.6.2025
20

Bourns Releases Automotive Impedance Matching Transformer

6.6.2025
11

5th PCNS Conference Registration Now Open!

5.6.2025
30

Bourns Releases Noise Suppression Common Mode SMD Inductors

4.6.2025
16

Passive Electronic Components Lead-times Update

4.6.2025
75

Upcoming Events

Jun 24
16:00 - 17:00 CEST

Limitations of PSFB converters and improvements by a variable inductor ft. Sam Ben-Yaakov

Jun 24
17:00 - 18:00 CEST

Ultra-Compact and Efficient Switched-Capacitor Power Converters

Jul 23
13:00 - 14:00 CEST

PCB design for a Smartwatch

View Calendar

Popular Posts

  • Buck Converter Design and Calculation

    0 shares
    Share 0 Tweet 0
  • Boost Converter Design and Calculation

    0 shares
    Share 0 Tweet 0
  • Flyback Converter Design and Calculation

    0 shares
    Share 0 Tweet 0
  • What is a Dielectric Constant and DF of Plastic Materials?

    4 shares
    Share 4 Tweet 0
  • LLC Resonant Converter Design and Calculation

    0 shares
    Share 0 Tweet 0
  • Ripple Current and its Effects on the Performance of Capacitors

    3 shares
    Share 3 Tweet 0
  • How to Design an Inductor

    0 shares
    Share 0 Tweet 0
  • SEPIC Converter Design and Calculation

    0 shares
    Share 0 Tweet 0
  • Dual Active Bridge (DAB) Topology Explained

    0 shares
    Share 0 Tweet 0
  • Flying Capacitors Explained

    0 shares
    Share 0 Tweet 0

Newsletter Subscription

 

Passive Components Blog

© EPCI - Leading Passive Components Educational and Information Site

  • Home
  • Privacy Policy
  • EPCI Membership & Advertisement
  • About

No Result
View All Result
  • Home
  • Knowledge Blog
  • Premium Suppliers

© EPCI - Leading Passive Components Educational and Information Site

This website uses cookies. By continuing to use this website you are giving consent to cookies being used. Visit our Privacy and Cookie Policy.
Go to mobile version