Fundamentals of Power Electronics

Appendix 2

Magnetics Design Tables

Geometrical data for several standard ferrite core shapes are listed here. The
geometrical constant Kg is a measure of core size, useful for designing inductors and
transformers which attain a given copper loss [1]. The Kg method for inductor design is
described in Chapter 13. Kg is defined as
A 2c WA
Kg =
MLT (A2.1)
where Ac is the core cross-sectional area, WA is the window area, and MLT is the winding
mean-length-per-turn. The geometrical constant Kgfe is a similar measure of core size, which
is useful for designing ac inductors and transformers when the total copper plus core loss is
constrained. The Kgfe method for magnetics design is described in Chapter 14. Kgfe is
defined as
WA A 2(1 – 1 / β)
K gfe = c
u(β)
MLT l 2e / β (A2.2)
where le is the core mean magnetic path length, and β is the core loss exponent:
P fe = K fe B βmax (A2.3)
For modern ferrite materials, β typically lies in the range 2.6 to 2.8. The quantity u(β) is
defined as

β+2
–
β β
– 2
β β +2 β β+ 2
u(β) = +
2 2
(A2.4)
u(β) is equal to 0.305 for β = 2.7. This quantity varies by roughly 5% over the range 2.6 ≤
β ≤ 2.8. Values of Kgfe are tabulated for β = 2.7; variation of Kgfe over the range 2.6 ≤ β ≤
2.8 is typically quite small.
 Appendix 2. Magnetics Design Tables

A2.1 Pot core data

A H

Core Geometrical Geometrical Cross- Bobbin Mean Magnetic Thermal Core

type constant constant sectional winding length path resistance weight
area area per turn length
(AH) Kg K gfe Ac WA MLT lm R th
(mm) cm5 cmx (cm2) (cm2) (cm) (cm) (˚C/W) (g)
-6 -6 -3
704 0.738·10 1.61·10 0.070 0.22·10 1.46 1.0 0.5
905 0.183·10-3 256·10-6 0.101 0.034 1.90 1.26 1.0
-3 -6
1107 0.667·10 554·10 0.167 0.055 2.30 1.55 1.8
1408 2.107·10-3 1.1·10-3 0.251 0.097 2.90 2.00 100 3.2
-3 -3
1811 9.45·10 2.6·10 0.433 0.187 3.71 2.60 60 7.3

2213 27.1·10-3 4.9·10-3 0.635 0.297 4.42 3.15 38 13

2616 69.1·10-3 8.2·10-3 0.948 0.406 5.28 3.75 30 20
-3
3019 0.180 14.2·10 1.38 0.587 6.20 4.50 23 34
3622 0.411 21.7·10-3 2.02 0.748 7.42 5.30 19 57
-3
4229 1.15 41.1·10 2.66 1.40 8.60 6.81 13.5 104

2
 Appendix 2. Magnetics Design Tables

A2.2 EE core data

Core Geometrical Geometrical Cross- Bobbin Mean Magnetic Core

type constant constant sectional winding length path weight
area area per turn length
(A) Kg K gfe Ac WA MLT lm
(mm) cm5 cmx (cm2) (cm2) (cm) (cm) (g)
-3 -3
EE12 0.731·10 0.458·10 0.14 0.085 2.28 2.7 2.34
EE16 2.02·10-3 0.842·10-3 0.19 0.190 3.40 3.45 3.29
-3 -3
EE19 4.07·10 1.3·10 0.23 0.284 3.69 3.94 4.83
EE22 8.26·10-3 1.8·10-3 0.41 0.196 3.99 3.96 8.81
-3 -3
EE30 85.7·10 6.7·10 1.09 0.476 6.60 5.77 32.4

EE40 0.209 11.8·10-3 1.27 1.10 8.50 7.70 50.3

EE50 0.909 28.4·10-3 2.26 1.78 10.0 9.58 116
-3
EE60 1.38 36.4·10 2.47 2.89 12.8 11.0 135
EE70/68/19 5.06 127·10-3 3.24 6.75 14.0 9.0 280

A2.3 EC core data

Core Geometrical Geometrical Cross- Bobbin Mean Magnetic Thermal Core

type constant constant sectional winding length path resistance weight
area area per turn length
(A) Kg K gfe Ac WA MLT lm R th
(mm) cm5 cmx (cm2) (cm2) (cm) (cm) (˚C/W) (g)
EC35 0.131 9.9·10-3 0.843 0.975 5.30 7.74 18.5 35.5
-3
EC41 0.374 19.5·10 1.21 1.35 5.30 8.93 16.5 57.0
EC52 0.914 31.7·10-3 1.80 2.12 7.50 10.5 11.0 111
-3
EC70 2.84 56.2·10 2.79 4.71 12.9 14.4 7.5 256

3
 Appendix 2. Magnetics Design Tables

A2.4 ETD core data

Core Geometrical Geometrical Cross- Bobbin Mean Magnetic Thermal Core

type constant constant sectional winding length path resistance weight
area area per turn length
(A) Kg K gfe Ac WA MLT lm R th
(mm) cm5 cmx (cm2) (cm2) (cm) (cm) (˚C/W) (g)
-3
ETD29 0.0978 8.5·10 0.76 0.903 5.33 7.20 30
ETD34 0.193 13.1·10-3 0.97 1.23 6.00 7.86 19 40
-3
ETD39 0.397 19.8·10 1.25 1.74 6.86 9.21 15 60
ETD44 0.846 30.4·10-3 1.74 2.13 7.62 10.3 12 94
-3
ETD49 1.42 41.0·10 2.11 2.71 8.51 11.4 11 124

A2.5 PQ core data

A1

2D

Core Geometrical Geometrical Cross- Bobbin Mean Magnetic Core

type constant constant sectional winding length path weight
area area per turn length
(A 1/2D) Kg K gfe Ac WA MLT lm
(mm) cm5 cmx (cm2) (cm2) (cm) (cm) (g)
-3 -3
PQ 20/16 22.4·10 3.7·10 0.62 0.256 4.4 3.74 13
PQ 20/20 33.6·10-3 4.8·10-3 0.62 0.384 4.4 4.54 15
-3 -3
PQ 26/20 83.9·10 7.2·10 1.19 0.333 5.62 4.63 31
PQ 26/25 0.125 9.4·10-3 1.18 0.503 5.62 5.55 36

PQ 32/20 0.203 11.7·10-3 1.70 0.471 6.71 5.55 42

-3
PQ 32/30 0.384 18.6·10 1.61 0.995 6.71 7.46 55
PQ 35/35 0.820 30.4·10-3 1.96 1.61 7.52 8.79 73
-3
PQ 40/40 1.20 39.1·10 2.01 2.50 8.39 10.2 95

4
 Appendix 2. Magnetics Design Tables

A2.6 American wire gauge data

AWG# Bare area, Resistance, Diameter,
10-3 cm2 10-6 Ω/cm cm
0000 1072.3 1.608 1.168
000 850.3 2.027 1.040
00 674.2 2.557 0.927
0 534.8 3.224 0.825
1 424.1 4.065 0.735
2 336.3 5.128 0.654
3 266.7 6.463 0.583
4 211.5 8.153 0.519
5 167.7 10.28 0.462
6 133.0 13.0 0.411
7 105.5 16.3 0.366
8 83.67 20.6 0.326
9 66.32 26.0 0.291
10 52.41 32.9 0.267
11 41.60 41.37 0.238
12 33.08 52.09 0.213
13 26.26 69.64 0.190
14 20.02 82.80 0.171
15 16.51 104.3 0.153
16 13.07 131.8 0.137
17 10.39 165.8 0.122
18 8.228 209.5 0.109
19 6.531 263.9 0.0948
20 5.188 332.3 0.0874
21 4.116 418.9 0.0785
22 3.243 531.4 0.0701
23 2.508 666.0 0.0632
24 2.047 842.1 0.0566
25 1.623 1062.0 0.0505
26 1.280 1345.0 0.0452
27 1.021 1687.6 0.0409
28 0.8046 2142.7 0.0366
29 0.6470 2664.3 0.0330
30 0.5067 3402.2 0.0294
31 0.4013 4294.6 0.0267
32 0.3242 5314.9 0.0241
33 0.2554 6748.6 0.0236
34 0.2011 8572.8 0.0191
35 0.1589 10849 0.0170
36 0.1266 13608 0.0152
37 0.1026 16801 0.0140
38 0.08107 21266 0.0124
39 0.06207 27775 0.0109
40 0.04869 35400 0.0096
41 0.03972 43405 0.00863
42 0.03166 54429 0.00762
43 0.02452 70308 0.00685

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 Appendix 2. Magnetics Design Tables