Speeding up transformer design through latest Web tool

1. Speeding up transformer design through latest Web tool Design Better Power Supply

2. The Web tool . . . • It’s on-line • It’s for everyone • Worldwide access • 100% server side simulation • It’s FREE !!

3. Free accounts from sponsors • Some sponsors provide a full features PowerEsim for public user.

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

5. I/P Votlage Vs Efficiency % Input Votlage Vs Efficiency % 100.00 100.00 90.00 90.00 80.00 80.00 70.00 70.00 60.00 60.00 50.00 50.00 40.00 40.00 30.00 30.00 20.00 20.00 10.00 160W PFC Input Voltage Vac 10.00 0.00 150W flybackInput Votlage Vdc 0.00 300 350 405 85 110 230 265 It’s highly accurate

6. Find MOSFET Find Diode Find Capacitor Find Core Find Wire No expert knowledge needed PowerEsim Traditional Design • Rds*Crss • Vf*trrm • CV • k1, k2, k3 • Current density • No equations needed! • Simple pick and place components • Or build real Xformer in virtual space

7. PowerEsim vs Traditional Design PowerEsim turn design into result oriented adaptive iteration instead of skill of knowledge application

8. Designing a power supply - Ask our expert • Enter the input & output specification • Chose an application • Click “Recommend Design”

9. Search for best topologies Specification How our expert inside the server work Search for closest reference design • Fuzzy logic is used to rank the topologies or reference design according to user’s requirements

10. Chose a PWM controller circuit • Double click the PWM block • Select the PWM controller • Another PWM circuit will appear

11. Preliminary 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

12. Now click T1 and go to Magnetic Builder

13. m=2 Proximity effect H Fringing flux Core losses Skin effect Background - What else we consider for a transformer Leakage inductance

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

15. Design a single Xformer – Where it apply? • Choose the application of the magnetic component, e.g. it is a “Flyback Xformer” or “Input Choke”

16. Design a single Xformer – 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.

17. Design a single Xformer – “Recommended 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.

18. Design a single Xformer – Full version Magnetic Builder • Click the “Advanced” button will go to the full version Magnetic Builder and do whatever you like.

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

20. Any real core you like • Chose the range of Ae • Select Core shape • Select Manufacturer

21. Instant preview winding when thing change • Click the “preview winding” • Corresponding winding cross section will be shown • Supported on Core, N and Wire.

22. Seeking 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.

23. Find 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.

24. No. of turn is not just an abstract number ! • Click the “Preview Winding” button • Observe how winding structure change with number of turn.

25. Add more copper • Click the “Change Wire” button • Click the “No. of Parallel Wire” • Add more parallel wire as you like.

26. Copper foil can be used • Click the “Use copper foil” button • Enter the copper foil size

27. Faraday 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.

28. Arrange each winding layer you like

29. The dot of a winding • User can define whether the winding is started at dot sign or not

30. Where to start • User can define whether the winding is started at upper end or lower end of the winding layer

31. How 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.

32. Layer 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

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

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

35. 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 . . . .

36. Transformer 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.

37. Thermal – knowing Temp. at day 1 • May be the fastest and easiest thermal simulation tool for power supply. 5 s for a simulation only!!

38. DVT – check the stresses • DVT Report check every components stress and also circuit design constraint.

39. MTBF – how long it last

40. Use 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

41. Loop Analysis– how stable the system • Gain and phase margin will be immediately known with after any change or circuit component

42. Loop Analysis– transient loading • Define step loading waveform and corresponding output transient loading response will be shown

43. Harmonic – knowing input current harmonics content • All input current parameters, e.g. PF, THD, harmonic content can be seen

44. Waveform – the least important tools • Critical component’s waveform will be illustrated

45. BOM Builder – BOM 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.

46. Report Builder – Generate all document with a click • Simple a click - All result from analysis or tools can be exported to Excel file for engineering documentation.

47. Download – a 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.

48. We believe . . . Making Engineer's Life More Easy