TRAFTOR WINDINGS CHANGING THE RULES TOROIDAL INDUCTORS & TRANSFORMERS SOLUTIONS PROVIDER AND MANUFACTURER

Transcription

1 TRAFTOR WINDINGS CHANGING THE RULES TOROIDAL INDUCTORS & TRANSFORMERS SOLUTIONS PROVIDER AND MANUFACTURER

2 PRODUCT RANGE POWER INDUCTORS Toroidal technology, driven by 20 years of R&D. POWER TRANSFORMERS 50 VA to 500 kva 500 VA to 100 kva 50 Hz to 100 khz PCB mounted high frequency - casted Toroidal round and flat wire, EI and C cores Interleaved inductors, mixed cores, autotransformer... Lamination, iron powder, amorphous, nano-crystalline magnetic cores Key customers World leaders in UPS market, Drives, Solar Energy, EV chargers, Automation, Robotic, industry leaders in power electronics TRAFTOR Technology Technical center, production and headquarters in P.R. China, Europe office 2 ISO 9001 and manufacturing facilities. Certified by its main customers.

3 AUTOMOTIVE, HEV MEDICAL RENEWABLE ENERGIES RAIL UPS, DRIVE INDUSTRIES 3

4 SOME OF OUR TOROIDAL PRODUCTS 1130µH/30A 13 cm 300µH/42A 7 cm 20 cm 13 cm 20 cm 16 cm 80µH/300A 320µH/125A 690µH/30A 120µH/300A 16kVA 340µH/170A 26 cm 20 cm 11 cm 4 3 x 2000µH/28A 13

5 SOME OF OUR OTHER PRODUCTS 5

6 6 TRAFTOR DESIGNS THE RIGHT SOLUTION FOR YOUR FUNCTIONAL NEEDS. Traftor cooperates with its customers to provide the RIGHT DESIGN through professional project management: For your functional needs. Integrated optimization, considering the application environment. Precise tools and software with multi-physics simulations, using the finite element method. Supply of the prototypes.

7 CHOOSE YOUR DESIGN TRAFTOR DEVELOPS ITS OWN DESIGN SOFTWARE TO LET YOU CHOOSE FROM HUNDREDS OF SOLUTION 1 Input Data, get hundreds of solutions. Choose 3 designs based on prices / losses ratio. 2 Compare DC bias and performances 3 Choose the best design 4 Choose appropriate mechanical shape for this design 5 Get full specifications in PDF Core manufacturer A Core manufacturer B Core manufacturer C Design Solution Platform «Entreprise 4.0» 7

8 BETTER PHYSICAL UNDERSTANDING OF CHOOSEN DESIGN TRAFTOR USES FINITE ELEMENT APPROACH SOFTWARE Once a solution has been chosen, simulation software will provide better physical understanding of several possible phenomena: proximity and skin effect, thermal characteristics 8

9 ADVANCED TECHNOLOGY : TRAFTOR MIXED CORES INDUCTORS DESIGN FOR INNOVATIVE CHOICES To stack different cores provides new possibilities. For example to combine good linearity material to a low losses material for better overall performance. To embed different cores for flat shape design inductors, can also be an interesting option. 9

10 TECHNOLOGY MATRIX OF INDUCTORS Classic EI, EE, C foil inductors Toroidal round wire inductor Flat wire toroidal inductor Material use efficiency Poor Good Excellent Magnetic field homogeneity Poor Excellent Excellent Manufacturing Process Hard Easy Easy Parasitic capacitance High Low Very low Insulation reliability Poor High Very high Cooling efficiency Poor High High High Power coil losses >100kVA Good Medium Poor DCR high power >100kVA Excellent Good Poor Filling factor Good Good Medium 10

11 INTRODUCTION TO TOROIDAL TECHNOLOGY Up to 2 times smaller and lighter Up to 20% lower cost Higher efficiency up to 98% (1) Lower acoustic noise Lower EMI (2) emission (1) For transformers. For inductors, we reach better performances. (2) EMI: electromagnetic interference. Read more on traftor.com 11 >

12 WHY TOROIDAL SOLUTION IS BETTER: LEAKAGE FLUX 12 E, EI AND C CORES High level of leakage flux from E core is creating acoustic noise in metal sheet and EMI (electromagnetic interference) in electronic systems. Read more on traftor.com > TOROIDAL CORE In toroidal technology, magnetic core is completely surrounded by the coils, allowing for a uniform magnetic field and reducing leakage flux. Traftor makes sure winding creates an uniform magnetic field.

13 WHY TOROIDAL SOLUTION IS BETTER: BETTER COOLING EFFICIENCY Thermal field in E magnetic core is not uniform, winding covering only 40-60% of magnetic core area (LIMB), creating hot spots and reducing cooling efficiency. Toroidal core is uniform, without hot spot. Toroidal core surface completely surrounded by coil + smaller coil thickness = improved cooling efficiency. THERMAL CONDUCTIVITY W/mK Copper 394 Aluminum 209 Iron Powder Core 2-6 Polyamide tape 0.12 Air Best cooling efficiency is achieved with toroidal shape, because 100% of the magnetic core is completely surrounded by winding of material of high thermal conductivity like copper or aluminium wire. Traftor designs according to your cooling system to achieve best results. 13

14 WHY TOROIDAL SOLUTION IS BETTER: IMPROVED RELIABILITY 14 EI and C cores create high parasitic capacitance everywhere which: worsens the electric field environment in coil, increases leakage current between layers and wires, creates partial discharge and corona effect, requires more insulation everywhere, increasing cost and reducing cooling efficiency. All of them are aging factors that can damage components of an insulated system and IGBT. With toroidal shape, only the first and last turn area needs more insulation. With toroidal core, only a few turns of coil with higher voltage stress need the use of reinforced insulation. Reliability is improved thanks to less aging factors due to lower parasitic capacitance. It can further be improved, using our VPI system (Vacuum Pressure Impregnation). Traftor takes care of reinforced insulation in critical areas.

15 WHY TOROIDAL SOLUTION IS BETTER: LOWER PARASITIC CAPACITANCE parasitic capacitance Toroidal core Many layers on E magnetic cores wound by foil or solid wire create big parasitic capacitance and worsen frequency properties. Read more on traftor.com > Toroidal magnetic core uses fewer coil layers, minimizing parasitic capacitance and significantly improving the high frequency properties for inductors and transformers. Traftor is able to wind wire diameter up to 5.5 mm that reduces also parasitic capacitance. 15

16 WHY TOROIDAL SOLUTION IS BETTER: LOWER EMI* E CORE FOIL, SOLID WIRE AND TOROIDAL INDUCTOR IMPEDANCES VS FREQUENCY expressed in db DIFFERENTIAL MODE NOISE FOR DIFFERENT INDUCTORS EI and C cores create high parasitic capacitance inducing high frequency voltage oscillations. It increases electromagnetic interference and electrical stress for insulation and IGBT. Lower parasitic capacitance from toroidal coil decreases high frequency oscillations. *EMI: electromagnetic interference The parasitic capacitance dominates the impedance above the self-resonant frequency of the inductor (typically MHz for power electronics applications). This parasitic capacitance reduces the impedance of an inductor at high frequencies and hence reduces its effectiveness for high frequency filtering. Toroidal inductors present the best high frequency properties, therefore reduce EMI. Traftor designs to get a minimum parasitic capacitance and therefore a reduction of EMI.

17 WHY TOROIDAL IRON POWDER CORES ARE BETTER: IRON POWDER CORES OFFER MORE AND MORE OPTIONS Cut cores technology creates fringing flux and eddy current in coil and magnetic core. Inductor reaches sharp saturation level because of the discrete gap structure, requiring a lot of headroom in the design. Discrete air gap structure in magnetic cores increase significantly the acoustic noise. Iron powder core with distributed air gap reduces fringing flux phenomena. The variety of iron powder materials allows for optimized magnetic and electrical properties of toroidal inductors: Inductance: a wide range of sizes and permeabilities available, Power : stacked cores option, Core losses : a choice at the design stage. Toroidal iron powder cores are available in a continuous wider range of characteristics and become more and more competitive. Traftor compares all material characteristics to get the best designs. 17

18 WHEN HIGHER FREQUENCIES ARE REQUIRED: TOROIDAL FLAT WIRE PERFORMANCE FLAT WIRE (FW) DESIGN ADVANTAGES: Lower parasitic capacitance FW design uses very few coil layers, minimizing parasitic capacitance and improving HF properties. Leading to a reduction of EMI. Higher insulation reliability Only a few turns of coil with higher voltage stress need reinforcement of insulation. Higher cooling efficiency FW behave as cooling fins in air flow system, leading to best efficiency of cooling system. 18

19 WHEN COST VS PERFORMANCE IS A MAJOR CONSTRAINT: TOROIDAL FLAT WIRE PRODUCTION ADVANTAGES FLAT WIRE (FW) DESIGN ADVANTAGES Facilitate winding process Only one wire by inductors Winding process takes 2 min/inductors. FACILITATE ASSEMBLY PROCESS Soldering process is better with only one wire. Insulation process is only needed for first and last turns. 19

20 Europe Office France Headquarters Technical Center and Factory Shenzhen SASU TRAFTOR EUROPE Thônes - France Tel. +33 (0) TRAFTOR TECHNOLOGY (SHENZHEN) Co, Ltd Shenzhen, P.R. China Tel. +86 (0) Contact us projects@traftor.com Learn more on