Transforming the Future of Power Electronics Planar ... A4 24pp Brochure.pdf · Transforming the...

Transforming the Future of Power Electronics

Planar Transformers & Inductors www.himag.co.uk

himag brochure cover final.indd 1 24/04/2012 16:40

Company ProfileHimag Planar Ltd. has pioneered planar transformer technology from the UK since 1996.Our world-leading design engineering team have developed custom planar transformers from 35W to 50kW in a single transformer component and inductors at 350A, as well as fully developing custom power converters utilising planar magnetics technology. This design facility is an essential part of the Himag Planar organisation as most products are custom designed.

Himag Planar offers a one-stop planar transformer and inductor service; from your initial design concept right through to volume production. We aim to work alongside our customer throughout the design lifecycle, from the drawing board to the finished product. Flexibility is our ethos: we design custom magnetic components and systems to suit your specific requirements, rather than expecting you to adapt your design to accommodate a standard part.

Awards

Himag Planar Limited won the UK finals of the prestigious Shell Springboard Award for the best low carbon business idea in the UK. The award was given at a ceremony in central London to recognise the innovation of its planar transformer which dramatically increases energy efficiency in high-frequency power electronic products across the world. As an invisible but integral component of millions of electrical devices, the Planar Transformer could have a huge impact on our domestic and global carbon footprints.

The Shell Springboard program has awarded over £1.6 million to 43 UK-based small businesses and this year celebrates its fifth anniversary. Eight companies have been given no-strings awards of £40,000 each at regional events in February. Himag Planar impressed the UK final judging panel, and out of the 6 UK finalists came top to gain the further title of Shell Springboard UK winner.

The judging panel comprised Tom Delay of the Carbon Trust, Lord Oxburgh, Ben Goldsmith of Wheb Ventures and Dr Douglas Parr, Chief Scientist, Greenpeace. The judges were particularly impressed with the potential of Himag planar transformers in the solar power, electric vehicles and aerospace markets.

Dean Curran, Managing Director of Himag Planar, said: “The financial boost from the Shell Springboard award will unlock the huge market potential for our energy efficient transformers - a fundamental component of thousands of electrical devices. We can now realise our ambition of providing a technology which tackles energy inefficiency at the very core to manufacturers far and wide. Without this award we wouldn’t be able to grow as fast but, above all, it’s the accolade of being named the Shell Springboard overall UK Winner which gives us real credibility in the eyes of our customers and potential investors alike.”

Planar Transformers

www.himag.co.uk1

Planar TransformersPlanar transformers are suited to high frequency switching applications, with a typical switching frequency of 5kHz - 500kHz. The fundamental difference between planar transformers and traditional wire-wound transformers is the planar’s use of flat copper windings, resulting in higher efficiency. Planar Windings are constructed using flat copper layers (‘lead-frames’) or printed circuit boards (PCBs) to form a laminate style winding construction, which are then sandwiched between small, light-weight planar ferrite cores. The result is a compact, high power density planar transformer that is typically around 30% of the volume and weight of its conventional wire-wound equivalent. As a result, bulky three dimensional wire-wound transformers will no longer constrain your design.

Advantages Applications• High Efficiency (>99%)

• Low profile (<40mm height)

• Lightweight (5g per 100W)

• Low Leakage Inductance

• Repeatability (Controlled Parasitics)

• Customised Terminations

• Highly Efficient Cooling

• Multiple Topologies

• Multiple Winding Options

• Dimensional Accuracy

• 4kV Isolation, typical

• Reduced EMI

• AUTOMOTIVE

o Electric Vehicle Battery Charging

o Hybrid/Electric Vehicle Drive Train

o Kinetic Energy Recovery

• RENEWABLE ENERGY

o Solar Inverters

o Wind Power

• TELECOMMUNICATIONS

• AEROSPACE

• HEALTHCARE

• DEFENCE

• LED LIGHTING

• INDUSTRIAL

o Motor Control Drives

o Welding

o Induction Heating

o Induction Charging

2www.himag.co.uk

Planar Transformers

Product Range Overview

OUTPUTPOWER FREQUENCY

INPUT/OUTPUT VOLTAGE

OUTPUTCURRENT PAGE

131000A MAX1000V MAX1MHz MAX30kW MAXSIZE 1080 ≥ ≥ ≥




9300A MAX750V MAX3MHz MAX6.5kW MAXSIZE 350 ≥ ≥ ≥




5120A MAX500V MAX3MHz MAX1.5kW MAXSIZE 195 ≥ ≥ ≥


141200A MAX1000V MAX1MHz MAX≥ ≥ ≥50kW MAXSIZE 1200



Transformers

Indu

ctor

s

www.himag.co.uk

[1]

PRODUCT RANGE OVERVIEW TRANSFORMERS

OUTPUT POWER

FREQUENCY INPUT/ OUTPUT

VOLTAGE OUTPUT

CURRENT PAGE

SIZE 130 1kW MAX ≤3MHz MAX ≤500V MAX ≤100A MAX 4

SIZE 195 1.5kW max ≤3MHz MAX ≤500V MAX ≤120A MAX 5

SIZE 225 2kW max ≤3MHz MAX ≤500V MAX ≤150A MAX 6



SIZE 350 6.5kW max ≤3MHz MAX ≤750V MAX ≤300A MAX 9






INDUCTORS

www.himag.co.uk3

Planar Transformers

Size: 130Size: 195Size: 225Size: 230Size: 310Size: 350Size: 500Size: 540Size: 560Size: 1080Size: 1200Size: 2400Size: 3600

SIZE 130 1kW MAX POWER

OUTPUTPOWER

INPUTVOLTAGE FREQUENCY

OUTPUTVOLTAGE

OUTPUTCURRENT

TURNSRATIO

PRIMARYINDUCTANCE

1kW MAX

Custom Transformer Parameters

500V MAX 3MHz MAX 500V MAX 100A MAX CUSTOM CUSTOM

Example Transformer SpecificationsOUTPUT POWER INPUT VOLTAGE FREQUENCY OUTPUT VOLTAGE

175W253W729W

100V - 300V20V - 30V

300V - 400V

100kHz250kHz150kHz

350V230V27V

0.5A1.1A27A

11:381:2032:7

OUTPUT CURRENT TURNS RATIO

Additional Technical InformationIsolation Voltage:

Primary - Secondary

Primary - Core

Secondary - Core

Switching Frequencies

Weight

4kVrms

2.5kVrms

2.5kVrms

20kHz-3MHz

45g (typ.)

www.himag.co.uk

[1]

SIZE 130 - 1KW MAX POWER

CUSTOM TRANSFORMER PARAMETERS

OUTPUT POWER

INPUT VOLTAGE FREQUENCY

OUTPUT VOLTAGE

OUTPUT CURRENT

TURNS RATIO

PRIMARY

INDUCTANCE

1kW MAX 500V MAX 3MHz MAX 500V MAX 100A MAX CUSTOM CUSTOM

EXAMPLE TRANSFORMER SPECIFICATIONS

OUTPUT POWER


OUTPUT VOLTAGE

OUTPUT CURRENT

TURNS RATIO

175W 100 – 300 100kHz 350V 0.5A 11:38

253W 20V – 30V 250kHz 230V 1.1A 1:20

729W 300V – 400V 150kHz 27V 27A 32:7

TOPOLOGIES

Full Bridge Half-Bridge Flyback Boost

Push Pull Resonant Forward Buck

ADDITIONAL TECHNICAL INFORMATION

Isolation Voltage:

Primary – Secondary 4kVrms

Primary – Core 2.5kVrms

Secondary – Core 2.5kVrms

Switching Frequencies 20kHz-3MHz

Weight 45g (typ.)

INDUCTOR SELECTION

50mm MAX

32m

m M

AX

11

mm

MIN

20

mm

MA

X

Topologies•Full Bridge

•Push Pull

•Half-Bridge

•Resonant

•Flyback

•Forward

•Boost

•Buck

Inductor Selection

4www.himag.co.uk

Planar Transformers

www.himag.co.uk

[1]

SIZE 195 - 1.5KW MAX POWER


OUTPUT POWER


OUTPUT VOLTAGE

OUTPUT CURRENT

TURNS RATIO

PRIMARY

INDUCTANCE

1.5kW MAX 500V MAX 3MHz MAX 500V MAX 120A MAX CUSTOM CUSTOM


OUTPUT POWER


OUTPUT VOLTAGE

OUTPUT CURRENT

TURNS RATIO

420W 20V – 40V 125kHz 28V 15A 2:6

800W 10V – 18V 100kHz 400V 2A 2:88

1.1kW 90V 250kHz 28V 40A 5:2

TOPOLOGIES




Isolation Voltage:





Weight 85g (typ.)

INDUCTOR SELECTION

60mm MAX

38m

m M

AX

12

mm

MIN

20

mm

MA

X

OUTPUTPOWER


OUTPUTVOLTAGE

OUTPUTCURRENT

TURNSRATIO

PRIMARYINDUCTANCE

1.5kW MAX




420W800W1.1kW

20V - 40V10V - 18V

90V

125kHz100kHz250kHz

28V400V28V

15A2A

40A

2:62:885:2



Primary - Secondary

Primary - Core

Secondary - Core


Weight

4kVrms

2.5kVrms

2.5kVrms

20kHz-3MHz

85g (typ.)


•Push Pull

•Half-Bridge

•Resonant

•Flyback

•Forward

•Boost

•Buck

Inductor Selection

SIZE 195 1.5kW MAX POWER

www.himag.co.uk5

Planar Transformers

www.himag.co.uk

[1]



OUTPUT POWER

INPUT VOLTAGE FREQUENCY OUTPUT

VOLTAGE OUTPUT

CURRENT TURNS RATIO

PRIMARY INDUCTANCE



OUTPUT POWER


OUTPUT VOLTAGE

OUTPUT CURRENT

TURNS RATIO

1000W 100V – 200V 75kHz 40V 25.0A 5:2

1.5kW 300V – 400V 100kHz 180V 8.30A 8:5

2.0kW 375V – 480V 250kHz 420V 4.75A 5:7

TOPOLOGIES

• Full Bridge • Half-Bridge • Flyback • Forward

• Resonant • Push Pull • Boost • Buck


Isolation Voltage:





Weight 110g (typ.)

INDUCTOR SELECTION

OUTPUTPOWER


OUTPUTVOLTAGE

OUTPUTCURRENT

TURNSRATIO

PRIMARYINDUCTANCE

2kW MAX




1kW2kW2kW

100V - 200V300V - 400V375V - 480V

75kHz100kHz250kHz

40V180V420V

25.0A8.30A4.75A

5:28:55:7



Primary - Secondary

Primary - Core

Secondary - Core


Weight

4kVrms

2.5kVrms

2.5kVrms

20kHz-3MHz

110g (typ.)


•Resonant

•Half-Bridge

•Push Pull

•Flyback

•Boost

•Forward

•Buck

Inductor Selection


www.himag.co.uk

[1]



OUTPUT POWER


VOLTAGE OUTPUT

CURRENT TURNS RATIO

PRIMARY INDUCTANCE



OUTPUT POWER


OUTPUT VOLTAGE

OUTPUT CURRENT

TURNS RATIO

1000W 100V – 200V 75kHz 40V 25.0A 5:2

1.5kW 300V – 400V 100kHz 180V 8.30A 8:5

2.0kW 375V – 480V 250kHz 420V 4.75A 5:7

TOPOLOGIES




Isolation Voltage:





Weight 110g (typ.)

INDUCTOR SELECTION

6www.himag.co.uk

Planar Transformers

www.himag.co.uk

[1]



OUTPUT POWER

INPUT VOLTAGE

FREQUENCY OUTPUT VOLTAGE

OUTPUT CURRENT

TURNS RATIO

PRIMARY

INDUCTANCE



OUTPUT POWER


VOLTAGE OUTPUT

CURRENT TURNS RATIO

400W 12V – 24V 60kHz 300V 1.3A 2:50

1.4kW 60V – 90V 100kHz 14V 100A 4:2

1.5kW 350V – 420V 75kHz 48V 30A 21:3

TOPOLOGIES




Isolation Voltage:





Weight 130g (typ.)

INDUCTOR SELECTION

65mm MAX

43

mm

MA

X

15

mm

MIN

2

4m

m M

AX

OUTPUTPOWER


OUTPUTVOLTAGE

OUTPUTCURRENT

TURNSRATIO

PRIMARYINDUCTANCE

2kW MAX




400W1.4kW1.5kW

12V 24V60V - 90V

350V - 420V

60kHz100kHz75kHz

300V14V48V

1.3A100A30A

2:504:2

21:3



Primary - Secondary

Primary - Core

Secondary - Core


Weight

4kVrms

2.5kVrms

2.5kVrms

20kHz-3MHz

130g (typ.)


•Resonant

•Half-Bridge

•Push Pull

•Flyback

•Boost

•Forward

•Buck

Inductor Selection


www.himag.co.uk7

Planar Transformers

www.himag.co.uk

[1]



OUTPUT POWER


OUTPUT VOLTAGE

OUTPUT CURRENT

TURNS RATIO

PRIMARY

INDUCTANCE



OUTPUT POWER


VOLTAGE OUTPUT

CURRENT TURNS RATIO

2.4kW 300V - 400V 100kHz 12V 200A 18:1

3.6kW 100V – 150V 200kHz 300V 12A 3.9

4kW 400V 50kHz 500V 8A 21:26

TOPOLOGIES




Isolation Voltage:





Weight 300g (typ.)

INDUCTOR SELECTION

100mm MAX

58m

m M

AX

15

mm

MIN

40

mm

MA

X

OUTPUTPOWER


OUTPUTVOLTAGE

OUTPUTCURRENT

TURNSRATIO

PRIMARYINDUCTANCE

5kW MAX




2.4kW3.6kW4kW

300V - 400V100V - 150V

400V

100kHz200kHz50kHz

12V300V500V

200A12A8A

18:13:9

21:26



Primary - Secondary

Primary - Core

Secondary - Core


Weight

4kVrms

2.5kVrms

2.5kVrms

20kHz-3MHz

300g (typ.)


•Push Pull

•Half-Bridge

•Resonant

•Flyback

•Forward

•Boost

•Buck

Inductor Selection


8www.himag.co.uk

Planar Transformers

OUTPUTPOWER


OUTPUTVOLTAGE

OUTPUTCURRENT

TURNSRATIO

PRIMARYINDUCTANCE

6.5kW MAX




570W1.8kW4.8kW

36V200V - 500V130V - 150V

100kHz100kHz75kHz

190V18V24V

3A100A200A

4:24+411:14:2



Primary - Secondary

Primary - Core

Secondary - Core


Weight

4kVrms

2.5kVrms

2.5kVrms

20kHz-3MHz

200g (typ.)


•Push Pull

•Half-Bridge

•Resonant

•Flyback

•Forward

•Boost

•Buck

Inductor Selection

SIZE 350 6.5kW MAX POWER

www.himag.co.uk

[1]



OUTPUT POWER


OUTPUT VOLTAGE

OUTPUT CURRENT

TURNS RATIO

PRIMARY

INDUCTANCE

6.5kW MAX 750V MAX 3MHz MAX 750V MAX 300A MAX CUSTOM CUSTOM


OUTPUT POWER


VOLTAGE OUTPUT

CURRENT TURNS RATIO

570W 36V 100kHz 190VDC 3A 4:24+4

1.8kW 200V – 500V 100kHz 18V 100A 11:1

4.8kW 130 – 150V 75kHz 24V 200A 4:2

TOPOLOGIES




Isolation Voltage:





Weight 200g (typ.)

INDUCTOR SELECTION

70mm MAX

51m

m M

AX

15

mm

MIN

24

m M

AX

www.himag.co.uk9

Planar Transformers

OUTPUTPOWER


OUTPUTVOLTAGE

OUTPUTCURRENT

TURNSRATIO

PRIMARYINDUCTANCE

10kW MAX




3.5kW5.4kW9kW

420V - 622V350V - 375V780V - 800V

100kHz75kHz

130kHz

29V120V350V

120A45A25A

12:1+110:416:8



Primary - Secondary

Primary - Core

Secondary - Core


Weight

4kVrms

2.5kVrms

2.5kVrms

20kHz-3MHz

400g (typ.)


•Push Pull

•Half-Bridge

•Resonant

•Flyback

•Forward

•Boost

•Buck

Inductor Selection

www.himag.co.uk

[1]



OUTPUT POWER

INPUT VOLTAGE


OUTPUT CURRENT

TURNS RATIO

PRIMARY

INDUCTANCE



OUTPUT POWER

INPUT VOLTAGE


OUTPUT CURRENT

TURNS RATIO

3.5kW 420V – 622V 100kHz 29V 120A 12:1+1

5.4kW 350V – 375V 75kHz 120V 45A 10:4

9kW 780V - 800V 130kHz 350V 25A 16:8

TOPOLOGIES




Isolation Voltage:





Weight 400g (typ.)

INDUCTOR SELECTION

118mm MAX

65m

m M

AX

17

mm

MIN

40

mm

MA

X


10www.himag.co.uk

Planar Transformers

OUTPUTPOWER


OUTPUTVOLTAGE

OUTPUTCURRENT

TURNSRATIO

PRIMARYINDUCTANCE

10kW MAX




3.0kW6.0kW10kW

400V - 600V550V - 800V600V - 800V

50kHz100kHz200kHz

40V200V100V

75A30A

100A

9:15:2

7:1+1



Primary - Secondary

Primary - Core

Secondary - Core


Weight

4kVrms

2.5kVrms

2.5kVrms

20kHz-3MHz

430g (typ.)


•Push Pull

•Half-Bridge

•Resonant

•Flyback

•Forward

•Boost

•Buck

Inductor Selection

www.himag.co.uk

[1]



OUTPUT POWER


VOLTAGE OUTPUT

CURRENT TURNS RATIO

PRIMARY INDUCTANCE



OUTPUT POWER


OUTPUT VOLTAGE

OUTPUT CURRENT

TURNS RATIO

3.0kW 400V – 600V 50kHz 40V 75A 9:1

6.0kW 550V – 800V 100kHz 200V 30A 5:2

10kW 600V - 800V 200kHz 100V 100A 7:1+1

TOPOLOGIES




Isolation Voltage:





Weight 430g (typ.)

INDUCTOR SELECTION


www.himag.co.uk

[1]



OUTPUT POWER


VOLTAGE OUTPUT

CURRENT TURNS RATIO

PRIMARY INDUCTANCE



OUTPUT POWER


OUTPUT VOLTAGE

OUTPUT CURRENT

TURNS RATIO

3.0kW 400V – 600V 50kHz 40V 75A 9:1

6.0kW 550V – 800V 100kHz 200V 30A 5:2

10kW 600V - 800V 200kHz 100V 100A 7:1+1

TOPOLOGIES




Isolation Voltage:





Weight 430g (typ.)

INDUCTOR SELECTION

70mm MIN108mm MAX

64m

m M

AX

18m

m M

IN45

mm

MA

X

Size 510

www.himag.co.uk11

Planar Transformers

OUTPUTPOWER


OUTPUTVOLTAGE

OUTPUTCURRENT

TURNSRATIO

PRIMARYINDUCTANCE

15kW MAX




9kW10kW

13.5kW

450V - 650V520V - 750V375V - 425V

100kHz50kHz60kHz

250V400V225V

37A25A60A

16:614:1212:8



Primary - Secondary

Primary - Core

Secondary - Core


Weight

5.5kVrms

2.75kVrms

2.75kVrms

20kHz-1MHz

1kg (typ.)


•Push Pull

•Half-Bridge

•Resonant

•Flyback

•Forward

•Boost

•Buck

Inductor Selection

www.himag.co.uk

[1]



OUTPUT POWER


OUTPUT VOLTAGE

OUTPUT CURRENT

TURNS RATIO

PRIMARY

INDUCTANCE



OUTPUT POWER


OUTPUT VOLTAGE

OUTPUT CURRENT

TURNS RATIO

9kW 450V – 650V 100kHz 250V 37A 16:6

10kW 520V - 750V 50kHz 400V 25A 14:12

13.5kW 375V – 425V 60kHz 225V 60A 12:8

TOPOLOGIES




Isolation Voltage:

Primary – Secondary 5.5kVrms




Weight 1kg (typ.)

INDUCTOR SELECTION

SIZE 540 15kW MAX POWER112mm MIN 135mm MAX

102m

m M

AX

22m

m M

IN48

mm

MA

X

12www.himag.co.uk

Planar Transformers

OUTPUTPOWER


OUTPUTVOLTAGE

OUTPUTCURRENT

TURNSRATIO

PRIMARYINDUCTANCE

30kW MAX




15kW17kW30kW

583V - 745V400V - 800V540V - 700V

75kHz45kHz

100kHz

65V200V350V

230A85A90A

9:116:8

16:6+6



Primary - Secondary

Primary - Core

Secondary - Core


Weight

5.5kVrms

2.75kVrms

2.75kVrms

20kHz-1MHz

2kg (typ.)


•Push Pull

•Half-Bridge

•Resonant

•Flyback

•Forward

•Boost

•Buck

Inductor Selection

www.himag.co.uk

[1]


POSS. MIN DIMENSIONS 194MM X 102MM X 22.5MM


OUTPUT POWER


VOLTAGE OUTPUT

CURRENT TURNS RATIO

PRIMARY INDUCTANCE



OUTPUT POWER


VOLTAGE OUTPUT

CURRENT TURNS RATIO

15kW 583V – 745V 75kHz 65V 230A 9:1

17kW 400V – 800V 45kHz 200V 85A 16:8

30kW 540V – 700V 100kHz 350V 90A 16:6+6

TOPOLOGIES




Isolation Voltage:





Weight 2kg (typ.)

INDUCTOR SELECTION

219MM MAX

135M

M M

AX

IN

C. H

EA

TS

INK

58

MM

MA

X


www.himag.co.uk

[1]


POSS. MIN DIMENSIONS 194MM X 102MM X 22.5MM


OUTPUT POWER


VOLTAGE OUTPUT

CURRENT TURNS RATIO

PRIMARY INDUCTANCE



OUTPUT POWER


VOLTAGE OUTPUT

CURRENT TURNS RATIO

15kW 583V – 745V 75kHz 65V 230A 9:1

17kW 400V – 800V 45kHz 200V 85A 16:8

30kW 540V – 700V 100kHz 350V 90A 16:6+6

TOPOLOGIES




Isolation Voltage:





Weight 2kg (typ.)

INDUCTOR SELECTION

219MM MAX

135M

M M

AX

IN

C. H

EA

TS

INK

58

MM

MA

X

www.himag.co.uk13

Planar Transformers

OUTPUTPOWER


OUTPUTVOLTAGE

OUTPUTCURRENT

TURNSRATIO

PRIMARYINDUCTANCE

50kW MAX




15kW25kW50kW

500V - 800V850V - 1000V800V - 1000V

75kHz100kHz200kHz

40V350V200V

375A72A

250A

12:1+112:55:1



Primary - Secondary

Primary - Core

Secondary - Core


Weight

5.5kVrms

2.75kVrms

2.75kVrms

20kHz-3MHz

1.5kg (typ.)


•Push Pull

•Half-Bridge

•Resonant

•Flyback

•Forward

•Boost

•Buck

Inductor Selection


www.himag.co.uk

[1]



OUTPUT POWER


VOLTAGE OUTPUT

CURRENT TURNS RATIO

PRIMARY INDUCTANCE



OUTPUT POWER


OUTPUT VOLTAGE

OUTPUT CURRENT

TURNS RATIO

15kW 500V – 800V 75kHz 40V 375A 12:1+1

25kW 850V – 1000V 100kHz 350V 72A 12:5

50kW 800V - 1000V 200kHz 200V 250A 5:1

TOPOLOGIES




Isolation Voltage:





Weight 1.5kg (typ.)

INDUCTOR SELECTION

www.himag.co.uk

[1]



OUTPUT POWER


VOLTAGE OUTPUT

CURRENT TURNS RATIO

PRIMARY INDUCTANCE



OUTPUT POWER


OUTPUT VOLTAGE

OUTPUT CURRENT

TURNS RATIO

15kW 500V – 800V 75kHz 40V 375A 12:1+1

25kW 850V – 1000V 100kHz 350V 72A 12:5

50kW 800V - 1000V 200kHz 200V 250A 5:1

TOPOLOGIES




Isolation Voltage:





Weight 1.5kg (typ.)

INDUCTOR SELECTION

177mm MIN237mm MAX

153m

m M

AX

40m

m M

IN62

mm

MA

X

14www.himag.co.uk

Planar Transformers

Planar Transformers

www.himag.co.uk15

OUTPUTPOWER


OUTPUTVOLTAGE

OUTPUTCURRENT

TURNSRATIO

PRIMARYINDUCTANCE

80kW MAX




80kW 650V 20kHz 400V 200A 13:10



Primary - Secondary

Primary - Core

Secondary - Core


Weight

5.5kVrms

2.75kVrms

2.75kVrms

20kHz-3MHz

5kg (typ.)


•Push Pull

•Half-Bridge

•Resonant

•Flyback

•Forward

•Boost

•Buck

Inductor Selection


www.himag.co.uk

[1]



OUTPUT POWER


VOLTAGE OUTPUT

CURRENT TURNS RATIO

PRIMARY INDUCTANCE



OUTPUT POWER


OUTPUT VOLTAGE

OUTPUT CURRENT

TURNS RATIO

15kW 500V – 800V 75kHz 40V 375A 12:1+1

25kW 850V – 1000V 100kHz 350V 72A 12:5

50kW 800V - 1000V 200kHz 200V 250A 5:1

TOPOLOGIES




Isolation Voltage:





Weight 1.5kg (typ.)

INDUCTOR SELECTION

153m

m M

AX

40m

m M

IN62

mm

MA

X

Size 2400

293mm

Planar Transformers

16www.himag.co.uk

OUTPUTPOWER


OUTPUTVOLTAGE

OUTPUTCURRENT

TURNSRATIO

PRIMARYINDUCTANCE

120kW MAX




120kW 750 - 820V 20kHz 685V 175A 15:13



Primary - Secondary

Primary - Core

Secondary - Core


Weight

5.5kVrms

2.75kVrms

2.75kVrms

20kHz-3MHz

10kg (typ.)


•Push Pull

•Half-Bridge

•Resonant

•Flyback

•Forward

•Boost

•Buck

Inductor Selection


www.himag.co.uk

[1]



OUTPUT POWER


VOLTAGE OUTPUT

CURRENT TURNS RATIO

PRIMARY INDUCTANCE



OUTPUT POWER


OUTPUT VOLTAGE

OUTPUT CURRENT

TURNS RATIO

15kW 500V – 800V 75kHz 40V 375A 12:1+1

25kW 850V – 1000V 100kHz 350V 72A 12:5

50kW 800V - 1000V 200kHz 200V 250A 5:1

TOPOLOGIES




Isolation Voltage:





Weight 1.5kg (typ.)

INDUCTOR SELECTION

153m

m M

AX

40m

m M

IN62

mm

MA

X

Size 3600

348mm

Auxiliary-Power Range

Custom Auxiliary Planar Transformers

Himag Planar manufactures a standard range of auxiliary power PCB transformers in the 10W to 55W power range. Designed specifically to offer high-voltage, low-current solutions, these planar transformers are ideal for multiple output auxiliary PSUs, in single and three phase mains powered systems:

Himag Planar also offers custom PCB auxiliary planar transformers where extreme custom capability is required. The table below is an example of a high winding count, multiple 17 output auxiliary PSU transformer for multiple axis motor drives.

Size A 35W

POWER RANGE FREQ RANGE TOPOLOGY INSULATION PRIMARYTEMP.

10W - 35WPSU Output 1

5V @ 2APSU Output 2 & 3

+15V @ 0.2APSU Output 424V @ 0.75A

50kHz Flyback 5kV -10 - 95 0C 250V - 900V

Size B 55W



5V @ 2APSU Output 2 & 3

+15V @ 0.25APSU Output 424V @ 1.5A




5V @ 1.5A +15V @ 0.2A 24V @ 0.75A 8V @ 0.1A 15V @ 0.25APSU Output 2 & 3 PSU Output 4 PSU Output 5 PSU Output 6 to 17


www.himag.co.uk17

Planar Transformers

Multi-Pin PCBMounting

Horizontal PCBMounting

Vertical PCBMounting

BoltedConnections

CustomisedExtendedLead-Frames

Bolted and SolderedConnections

Power SolderedLeads

Fly Leads

Vertical PCB to PCB

Heatsinks

TerminationsHimag Planar offers a wide range of connection/termination options for its transformers. Some examples of existing designs are shown below. The Himag Planar design and are happy to provide any custom termination arrangement.

Himag Planar offers a wide range of heatsink and baseplate options for its transformers. Some examples of existing designs are shown below. The Himag Planar design and are happy to provide any custom heatsink or baseplate arrangement.

www.himag.co.uk 18

Planar Transformers

Quality

005

ISO 9001:2008

Himag Planar has been accredited under the ISO 9001:2000 system for a number of years and IS0 9000:2008 accreditation since 2010.

UL (UNDERWRITERS LABORATORIES)

Himag Planar products are manufactured to our own UL Certified Class F (+155oC) Insulation System (UL File No. E208723)

BRITISH

Most of our business activities, including R&D and low volume manufacturing (<10,000 per annum), is conducted from our base in the UK, in south-west England.

CHINA

Volume manufacturing for quantities above 10,000 parts per annum carried out in Himag Chinese manufacturing location.

www.himag.co.uk19

Planar Transformers

Custom DesignHimag Planar have been providing planar power solutions for over 13 years, offering an array of products and services to the power electronics market. We appreciate that not all designs fit into our standard product ranges and that’s why we also offer a custom design service.

We undertake projects ranging from discrete planar components to fully integrated power converters. The following are some examples of projects we have completed.

Power ConverterThe example shown below is a fully integrated planar magnetic, high voltage DC-DC Converter for a telecoms application. This is a resonant based design operating at a switching frequency of 20kHz. The converter runs from a low voltage DC Bus and is capable of delivering a high voltage output of up to 4kV @ 1Adc.

The main power transformer and output inductors are embedded within a single multilayer PCB. All other discrete components are mounted as either SMT or PTH devices on the same multilayer layer PCB:

•Rectification Diodes (SMT)

•Filter Capacitors (PTH)

•Feedback components (PTH)

•Protection Devices (PTH)

The incorporation of the magnetic components into a single PCB provides a compact solution with excellent repeatability. It also eases manufacture as there is less assembly time associated with its construction.

www.himag.co.uk 20

Planar Transformers

Integrated MagneticsWhere size and space are a real issue, integrated magnetics can provide an alternative solution to the conventional discrete component approach.Himag Planar has experience designing this type of product and this particular example, shown to the right, shows an integrated Transformer and Output Inductor assembly. This solution embeds a transformer with two inductors onto the same PCB assembly. These three components are configured for a current doubler output providing 5V @ 60Adc.

Retro FitNon-planar cores are often used when retro-fitting a planar transformer into a conventional space. Himag Planar has been asked on several occasions to design a retrofit planar transformer to replace a conventional transformer that ran too hot. A retro-fit planar transformer offers a combination of advantages, in particular the interleaving that a planar transformer construction allows, as well as a reduction of skin effect. Retro-fitting can present its own problems in terms of core selection and lead-frame/PCB design options, but has nevertheless yielded benefits. The reduction in thermal conduction area can be detrimental but as long as careful attention is paid to the interleave structure the majority of the benefits are still achievable.

High Voltage Isolation Transformers / FlexibilityHigh voltage isolation (up to 20kV) can present a challenge to any insulation system. Himag Planar overcome this by isolating one set of windings using HV Insulated wire. This allows the use of planar leadframes and PCB’s for the other winding set; greatly improving transformer size and performance. In addition Himag Planar also design transformers using multiple ferrite cores which greatly improves the effective area of the transformer. We design our own custom bobbins and fixtures to fit any combination.

www.himag.co.uk21

Planar Transformers

Contact UsHeadquarters

Himag Planar Magnetics Ltd.Unit A, The Aquarius Centre,Edison Close, Waterwells Business Park,Quedgeley, Glos.GL2 2FNUnited Kingdom

Tel: +44 (0) 1452 72 23 51

Fax: +44 (0) 1452 88 13 60

E-mail: [email protected]

005

www.himag.co.uk

Himag Planar Magnetics Ltd.Unit A, The Aquarius Centre, Edison Close, Waterwells Business Park, Quedgeley,

Glos. GL2 2FN United Kingdom.

www.himag.co.uk

Transforming the Future of Power Electronics Planar ... A4 24pp Brochure.pdf · Transforming the...

Documents

Transcript of Transforming the Future of Power Electronics Planar ... A4 24pp Brochure.pdf · Transforming the...