High-Current Chokes Using Iron PowderIntroductionGeneral Design ConsiderationsSlide 4Guidelines for choosing the type of powder coresReason for selecting Iron Powder CoresMethods to Design Iron Powder E-Core ChocksSlide 8Graphical Area Product method (Steps)Graphical Area Product method (Tables)Advantages/Disadvantages to using Graphical Area Product Method and PExprt SoftwareExample of Iron Powder E-Core Choke DesignExample of Iron Powder E-Core Choke Design (PExprt)Cont…Slide 15Slide 16Slide 17Conclusion01/13/1901/13/19EE136 Project by Alireza YavariEE136 Project by Alireza Yavari11High-Current Chokes High-Current Chokes Using Iron PowderUsing Iron PowderAlireza YavariAlireza YavariEE136 Final ProjectEE136 Final Project12-6-0312-6-0301/13/1901/13/19EE136 Project by Alireza YavariEE136 Project by Alireza Yavari22What is Chock?What is Chock?Chock is an inductor specifically designed to Chock is an inductor specifically designed to carry a large DC current componentcarry a large DC current componentWhat is Iron Powder?What is Iron Powder?Iron powder cores constructed from finely Iron powder cores constructed from finely divided ferromagnetic material bonded divided ferromagnetic material bonded together by a nonmagnetic material together by a nonmagnetic material IntroductionIntroduction01/13/1901/13/19EE136 Project by Alireza YavariEE136 Project by Alireza Yavari33General Design ConsiderationsGeneral Design ConsiderationsAmount of energy an inductor stores Amount of energy an inductor stores (Formula: 1/2 LI 2)(Formula: 1/2 LI 2) High permeability core materials High permeability core materials DC saturation characteristics of iron DC saturation characteristics of iron powder (Figure 1.1)powder (Figure 1.1)01/13/1901/13/19EE136 Project by Alireza YavariEE136 Project by Alireza Yavari4401/13/1901/13/19EE136 Project by Alireza YavariEE136 Project by Alireza Yavari55Guidelines for choosing the type Guidelines for choosing the type of powder coresof powder cores1)1)DC Bias Current through the inductorDC Bias Current through the inductor2)2)Ambient Operating Temperatures and Ambient Operating Temperatures and acceptable temperature rise acceptable temperature rise 3)3)Size constraint and mounting methods Size constraint and mounting methods 4)4)Costs Costs 5)5)Electrical stability of the core with Electrical stability of the core with temperature changes temperature changes 6)6)Availability of the core material Availability of the core material01/13/1901/13/19EE136 Project by Alireza YavariEE136 Project by Alireza Yavari66Reason for selecting Iron Powder Reason for selecting Iron Powder CoresCores1.1.Most Cost EffectiveMost Cost Effective2.2.Availability in permeabilities from 1 to Availability in permeabilities from 1 to 100 100 3.3.Contain saturation flux density (10,000 Contain saturation flux density (10,000 to 15,000 gauss)to 15,000 gauss)4.4.Operating temperature is limited to below Operating temperature is limited to below 125 deg C 125 deg C01/13/1901/13/19EE136 Project by Alireza YavariEE136 Project by Alireza Yavari77Methods to Design Iron Powder Methods to Design Iron Powder E-Core ChocksE-Core ChocksGraphical Area Product method (Fig. 1.2)Graphical Area Product method (Fig. 1.2)Using PExprt SoftwareUsing PExprt Software01/13/1901/13/19EE136 Project by Alireza YavariEE136 Project by Alireza Yavari8801/13/1901/13/19EE136 Project by Alireza YavariEE136 Project by Alireza Yavari99Graphical Area Product method Graphical Area Product method (Steps)(Steps)1.1.Establish the core size (Fig 1.2)Establish the core size (Fig 1.2)2.2.Calculate the number of turns Calculate the number of turns [N = ( L * I * 10 ^4 )/ (B * Ae )][N = ( L * I * 10 ^4 )/ (B * Ae )]3.3.Calculate the initial permeability [µr Calculate the initial permeability [µr = ( le * L * 10¯¹ ) / ( µ0 * N ² *Ac )]= ( le * L * 10¯¹ ) / ( µ0 * N ² *Ac )]4.4.Select the nearest core material Select the nearest core material 5.5.Calculate the DC magnetizing force Calculate the DC magnetizing force HHDCDC [ [HHDC DC = (0.4 П * N * I) / (le)]= (0.4 П * N * I) / (le)]6.6.Calculate the permeability of the selected core (Fig. 1.1)Calculate the permeability of the selected core (Fig. 1.1)7.7.If the air gap is required, establish the effective length of the air gap If the air gap is required, establish the effective length of the air gap [lg = ( le / µx) – ( le / µr ) mm] [lg = ( le / µx) – ( le / µr ) mm]8.8.Calculate wire size and winding resistance (Table 3.2.2)Calculate wire size and winding resistance (Table 3.2.2)9.9.Calculate the copper loss (Fig 1.2)Calculate the copper loss (Fig 1.2)01/13/1901/13/19EE136 Project by Alireza YavariEE136 Project by Alireza Yavari1010Graphical Area Product method Graphical Area Product method (Tables)(Tables)01/13/1901/13/19EE136 Project by Alireza YavariEE136 Project by Alireza Yavari1111Advantages/Disadvantages to using Graphical Advantages/Disadvantages to using Graphical Area Product Method and PExprt SoftwareArea Product Method and PExprt SoftwareAdvantagesAdvantages Area Product Method:Area Product Method:NoneNonePExprt Software:PExprt Software:More accurateMore accurateProvides detailsProvides detailsDisadvantagesDisadvantagesArea Product Method:Area Product Method:Time consuming Time consuming Human ErrorHuman ErrorPExprt Software:PExprt Software:Difficulty matching the dataDifficulty matching the data01/13/1901/13/19EE136 Project by Alireza YavariEE136 Project by Alireza Yavari1212Example of Iron Powder E-Core Example of Iron Powder E-Core Choke DesignChoke Design Using Graphic AreaUsing Graphic AreaUsing PExprtUsing PExprt01/13/1901/13/19EE136 Project by Alireza YavariEE136 Project by Alireza Yavari1313Example of Iron Powder E-Core Example of Iron Powder E-Core Choke DesignChoke Design (PExprt) (PExprt)01/13/1901/13/19EE136 Project by Alireza YavariEE136 Project by Alireza Yavari1414Cont…Cont…01/13/1901/13/19EE136 Project by Alireza YavariEE136 Project by Alireza Yavari1515Cont…Cont…01/13/1901/13/19EE136 Project by Alireza YavariEE136 Project by Alireza Yavari1616Cont…Cont…01/13/1901/13/19EE136 Project by Alireza YavariEE136 Project by Alireza Yavari1717Cont…Cont…01/13/1901/13/19EE136 Project by Alireza YavariEE136 Project by Alireza
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