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Here are the steps, along with the design flow diagram for the coupled-inductor design example: 1. Complete specification. 2. Pick a core 3. Calculate inductance and turns based on Al. 4. Calculate copper loss. 5. Calculate flux density and core loss. 6. Calculate temperature rise 7. Reiterate as required to get the turns to layer nicely on the core for good coupling and low leakage inductance.
This is Our Design Flow Summary
Inductor Design - MAGNETICS DC Bias data for gaped application
The above curves represent the locus of points up to which effective permeability remains constant. They show the maximum allowable DC bias, in ampere-turns, without a reduction in inductance. Beyond this level, inductance drops rapidly. Example: How many ampere-turns can be supported by an R42213A315 pot core without a reduction in inductance value? le = 3.12 cm μe = 125 Maximum allowable H = 25 Oersted (from the graph above) NI (maximum) = 0.80 x H x le = 62.4 ampere-turns or (Using top scale, maximum allowable H = 20 AT/cm.) NI (maximum) = AT/cm x le = 20 x 3.12 = 62.4 AT
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