Magnetic components (like transformers and inductors) are a critical part of switching power supplies(buck converter, boost converter, forward, flywheel converters, half and full bridge converters etc). They play a major role in ensuring the power supply operates efficiently and reliably. While their design can be complex, this process can be simplified by focusing on the specific needs of switching power supplies, without diving into all the theoretical details.
Simplified Design Steps:
Choose the Core Material:
- Select a material suitable for the intended application and the frequency the power supply operates at.
Pick the Core Shape:
- Choose a shape that meets the design requirements and complies with any regulatory standards.
Determine Core Size:
- Calculate how big the core needs to be to handle the required power output.
Decide on Air Gap and Windings:
- Check if an air gap is needed in the core (to control magnetic properties).
- Calculate how many wire turns are needed for each winding.
- Verify that the design meets voltage accuracy requirements and fits within the core's physical size.
Physically Wind the Core:
- Use recommended techniques to wind the wires around the core properly.
Test and Adjust:
- Build a prototype and test it for key parameters like:
- Voltage spikes.
- Accuracy of outputs.
- Ripple and noise levels.
- Radio-frequency interference (RFI).
- Make corrections if necessary.
- Build a prototype and test it for key parameters like:
Key Points to Understand:
Importance of Magnetic Components:
- They are essential for transferring and regulating energy in a power supply.
- Proper design ensures reliability and good performance.
Estimates and Adjustments:
- Calculations for magnetic components aren't exact; they provide an estimate.
- Slight adjustments during design can optimize aspects like size, input range, or efficiency.
