Construction and Simulation of a Planar Transformer Prototype

Sebastián Guarín,Sergio Velarde,Alexander Molina-Cabrera,Edwin Castaño

doi:10.32397/tesea.vol2.n2.1

Abstract

This paper illustrates the design and building of a planar transformer prototype with a 1:1 transformation ratio for high-frequency applications in power electronics. By using reference literature and considering the ferrite core dimensions, the windings were conceived and exported to Gerber format using PCB design software. The transformer prototype was then assembled and tested under laboratory conditions for frequencies from 800 Hz to 5 MHz, which showed a sinusoidal wave at the transformer output from 1.3 kHz onwards and a better performance starting at 10 kHz, where the loses were significantly reduced and the transformation ratio was closer to the originally designed. As a final step, a finite element method (FEM) análisis was carried out to understand the electromagnetic flux behavior using a 3D Multiphysics simulation software. The 3d building process and details are explained step by step and the resulting magnetic flux density is graphically shown for the core and the windings.

Highlights

C LIMATE change has motivated the rise of new ways to generate energy such as solar panels and wind power
The transformer prototype was assembled and tested under laboratory conditions for frequencies from 800 Hz to 5 MHz, which showed a sinusoidal wave at the transformer output from 1.3 kHz onwards and a better performance starting at 10 kHz, where the loses were significantly reduced and the transformation ratio was closer to the originally designed
Smart Grids require power converters, which typically work at high frequencies and include devices known as planar transformers (PT) [3]

Summary

INTRODUCTION

C LIMATE change has motivated the rise of new ways to generate energy such as solar panels and wind power. The main reasons that motivated the development of the planar transformer relied on the need to miniaturize powerhandling components such as the transformer itself [8], [9], mostly for high frequency and high-power density usage. This reduction in size and format, would simplify a low-profile assembly, making it adaptable to a low-cost mass production, contrary to the conventional transformer [10]. Estrov in [11] patented a “Switching electrical power supply utilizing miniature inductors integrally in a PC” This development greatly simplified the study of planar devices. In nowadays industry the core can be completely personalized, there are 4 shapes that are often available in the market (see Figure 2): EE, ER, EQ and PQ [7], [19], [20]

CONSTRUCTION OF THE PROTOTYPE

Windings

TRIDIMENSIONAL SIMULATION

Simulation results The fundamental study that was conducted is “Magnetic