CN112966405A - NR type power inductor and optimization design method based on finite element simulation - Google Patents
NR type power inductor and optimization design method based on finite element simulation Download PDFInfo
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Abstract
The invention discloses an NR type power inductor and an optimization design method based on finite element simulation, wherein the optimization design method comprises the following steps: a. selecting a magnetic core material according to a design target, and preliminarily determining the number of winding turns, the size of a center pillar of the magnetic core, the wire diameter of a lead and DCR parameters; b. carrying out parametric modeling in Maxwell to obtain a simulation model; c. carrying out finite element simulation by taking the saturation current of the NR type power inductor as a research object to obtain an L-I curve; d. adjusting parameters and repeating the steps b and c to obtain a plurality of corresponding L-I curves; e. comparing and determining the optimal structure. In the finite element simulation, the saturated current of the NR type power inductor is taken as a research object, so that the change of the inductor and the saturated current of the NR type power inductor under different center pillar sizes under the condition that the direct current resistance is minimum can be more accurately and quickly obtained, and an optimal structure design scheme is obtained.
Description
Technical Field
The invention relates to the technical field of design of magnetic components, in particular to an NR type power inductor structure optimization design method based on finite element simulation.
Background
With the demand of high frequency, the miniaturized large-current inductor is gradually applied to the fields of 5G base stations, industrial control mainboards, notebook computers, vehicle-mounted equipment, distribution power systems, DC/DC converters, LED driving power supplies, communication equipment, medical equipment, military electronics, aerospace technologies and the like. The specific requirements of the large-current inductor are small volume, large current, and good temperature rise current and saturation current under high-frequency and high-temperature environments. For the NR type inductor, the most outstanding problem is the design contradiction between low DCR (Direct Current Resistance) and high saturation Current.
In the design of the inductor, due to the limitation of materials and sizes, the winding space is limited, the low DCR and the high saturation current are mutually restricted, and the sectional areas of the blades and the center pillar of the NR type magnetic core are kept balanced as much as possible according to the traditional magnetic core structure design principle. When the structure design of heavy current inductance, this kind of traditional structural design principle leads to inductance wire winding space to reduce, and the effective utilization space is not enough, causes the inductance characteristic that the inductance product can't reach the requirement, for example: the L value (inductance value), DCR, saturation current affect each other, for example: when requiring high saturation current, the center pillar need be toward jumbo size design, and in traditional structural design principle, center pillar sectional area and magnetic core blade sectional area need keep balance, so the blade thickening, the wire winding space reduces, at this moment, will reach corresponding inductance value, and the copper line footpath can only select little footpath, and DCR will be big. As described above, DCRs contradict each other, the saturation current is small, and the DCR may be large; when the DCR is large, the saturation current may be small. Because the magnitude and direction of the mutual influence cannot be determined in advance, the traditional design method cannot solve the problem of the design contradiction.
The above background disclosure is only for the purpose of assisting in understanding the inventive concepts and technical solutions of the present application and does not necessarily pertain to the prior art of the present application, and should not be used to assess the novelty and inventive step of the present application in the absence of explicit evidence to suggest that such matter has been disclosed at the filing date of the present application.
Disclosure of Invention
In order to overcome the problem that the design contradiction existing in the design of the NR type power inductor structure cannot be solved in the prior art, the invention provides an NR type power inductor structure optimization design method based on finite element simulation, which comprises the following steps:
a. selecting a magnetic core material according to a design target, and preliminarily determining the number of winding turns, the size of a center pillar of the magnetic core, the wire diameter of a lead and DCR parameters;
b. b, carrying out parametric modeling in Maxwell on the basis of the parameters obtained in the step a to obtain a simulation model;
c. introducing the B-H curve of the magnetic core material into the simulation model, and carrying out finite element simulation by taking the saturation current of the NR type power inductor as a research object to obtain an L-I curve;
d. adjusting the number of turns of the winding wire in the step a for more than two times, and repeating the step b and the step c to obtain an L-I curve corresponding to each adjusted number of turns of the winding wire;
e. and d, comparing the L-I curves obtained in the step d, and determining an optimal structure.
The invention may also employ the following alternatives:
the parameters considered when selecting the magnetic core material in the step a at least comprise the voltage and the working frequency of the inductor in the normal working state, and the size and the inductance value of the NR type power inductor product.
The design objective in the step a is as follows: the operating frequency is 1MHz, the voltage is 1V, the inductance value is 1.0 muh, the size of the NR-type power inductor product is 2.5mm × 2.0mm × 1.2mm, and DCR is less than or equal to 0.025 Ω.
The magnetic core material is carbonyl iron powder alloy.
In the step d, the size of the magnetic core middle column is adjusted and simulated respectively on the basis of the number of winding turns and/or the adjusted basis in the step a, so that each corresponding L-I curve is obtained.
And adjusting the size of the column in the magnetic core to increase by taking 0.85mm as a starting point and by stepping to 0.05 mm.
The optimal structure is determined as follows: the design target is met, and the saturation current of the NR type power inductor is maximum.
The invention also provides an NR type power inductor, wherein the NR type power inductor structure comprises an I-shaped magnetic core, a flat coil or a round coil wound on a magnetic core center post of the I-shaped magnetic core, a magnetic plastic package layer covering the magnetic core and the flat coil or the round coil, and two electrodes connected with two leading-out ends of the flat coil or the round coil, wherein the two electrodes are exposed outside the magnetic plastic package layer.
Preferably, the width direction of the flat wire of the flat coil is perpendicular to the axial direction of the magnetic core center pillar, and the flat wire is stacked layer upon layer in the axial direction of the magnetic core center pillar.
Still preferably, the NR-type power inductor is designed by any one of the above-described optimization design methods.
Compared with the prior art, the invention has the beneficial effects that:
in the finite element simulation, the saturated current of the NR type power inductor is taken as a research object, so that the change of the inductor and the saturated current of the NR type power inductor under different center pillar sizes under the condition that the direct current resistance is minimum can be more accurately and quickly obtained, and an optimal structure design scheme is obtained.
Drawings
Fig. 1 is a flow chart of an NR-type power inductor structure optimization design method based on finite element simulation according to an embodiment of the present invention.
FIG. 2 is an L-I plot in an optimized design for one embodiment including three L-I curves for three different winding configurations.
Figure 3 is a schematic cross-sectional view of an inductor winding structure of one embodiment.
Detailed Description
The present invention will be described in further detail with reference to the following detailed description and accompanying drawings. Wherein like reference numerals refer to like parts unless otherwise specified. It should be emphasized that the following description is merely exemplary in nature and is not intended to limit the scope of the invention or its application.
Description/definition of related art terms:
the NR inductor is also called an automated shield inductor because it is manufactured by a fully automated machine, and is first introduced by solar induction in japan, and is also known as an NR inductor (number for tai chi induction) by many people.
The saturated current is taken as a research object, namely the current Isat is taken as a main electrical property representation index, the structure is changed, and the NR type power inductor structure is optimally designed. Saturation Current (Saturation Current) is commonly referred to as "Isat" and japanese corporation is also commonly referred to as DCI 1. According to the international standard unit system, the saturation current unit is ampere and is represented by 'A'. Generally, the value of the current at which the L value decreases by 30% is referred to.
The following is an analytical description of the relevant concepts of the present invention.
The prior design concept holds that the effective utilization rate of the inductance device can be kept higher only if the sectional areas of the blade and the middle column are equal. Therefore, when the center pillar cross-sectional area is equal to the blade cross-sectional area at the time of design, the structure is considered to be optimal. However, the inventor found that when the sectional area of the center pillar is increased, the blade needs to be thickened, which results in a reduction in winding space, so that the size of the center pillar cannot be determined, and thus an optimal structural design cannot be obtained. The inventor further researches to find that the blade cannot be limited due to the fact that the cross section area of the center pillar is too large, so that the blind problem of selecting the center pillar structure after the inductor blade is preferentially saturated is solved by taking device saturation current as a research object, the inductor structure and the number of winding turns can be determined in a short time period, and the problem of optimizing design of a large-current magnetic component is finally solved. The optimization design method of the present invention is summarized as the flow chart shown in fig. 1, so as to understand, specifically, the following steps are performed:
inputting electrical requirements, such as voltage and working frequency of the inductor in a normal working state, and determining the size, inductance value and the like of a product;
adjusting parameters by calculating tables and outputting DCR;
obtaining a magnetic core structure, wire diameter, number of turns (turns) and the like;
after modeling, substituting the model into an MAXWELL simulation model, and simultaneously inputting a mu e curve and a magnetic core B-H curve to perform finite element simulation;
after simulation, outputting an L value (the inductance value of a wound inductor product or a glued inductor product) and L-I data;
judging whether the L value and the L-I data reach the specification or not, namely selecting the one which meets the requirement design and corresponds to the maximum saturation current, namely the optimal structure;
if so, outputting the scheme; if not, returning to the step of adjusting parameters through the calculation table and outputting the DCR, repeating the operation until the L value and the L-I data reach the specification, and ending.
Example one
An NR type power inductance structure optimization design method based on finite element simulation comprises the following steps:
a. selecting a magnetic core material according to a design target, and preliminarily determining the number of winding turns, the size of a center pillar of the magnetic core, the wire diameter of a lead and DCR parameters;
b. b, carrying out parametric modeling in Maxwell on the basis of the parameters obtained in the step a to obtain a simulation model;
c. introducing the B-H curve of the magnetic core material into the simulation model, and carrying out finite element simulation by taking the saturation current of the NR type power inductor as a research object to obtain an L-I curve;
d. adjusting the number of turns of the winding wire in the step a for more than two times, and repeating the step b and the step c to obtain an L-I curve corresponding to each adjusted number of turns of the winding wire;
e. and d, comparing the L-I curves obtained in the step d, and determining an optimal structure.
In this embodiment, the magnetic core material is carbonyl iron powder alloy; the design objective in the step a is as follows: the operating frequency is 1MHz, the voltage is 1V, the inductance value is 1.0 muh, the size of the NR-type power inductor product is 2.5mm × 2.0mm × 1.2mm, and DCR is less than or equal to 0.025 Ω.
The determination of the optimal structure is to consider the following two conditions simultaneously: firstly to meet the design goals and secondly to maximize the saturation current of the NR-type power inductor.
Preferably, in the step d, the size of the column in the magnetic core is adjusted and simulated respectively on the basis of the number of turns of the winding wire in the step a and/or on the basis of the adjusted winding wire, so as to obtain each corresponding L-I curve. And adjusting the size of the column in the magnetic core to increase by taking 0.85mm as a starting point and by stepping to 0.05 mm. Then, L-I curves of different center pillar structures are drawn, and a magnetic core structure design with the optimal saturation current is selected according to each L-I curve, that is, the target NR-type power inductor structure design of the present embodiment. As shown in the L-I graph of fig. 2, it can be seen that the NR-type power inductor structure corresponding to the second dot from right to left (Iset ═ 5A, L ═ 1 μ H) in the middle L-I curve is optimal under the premise of satisfying the design objective. 6.5T, 7.5T and 8.5T in the figure represent the number of winding turns of 6.5 turns, 7.5 turns and 8.5 turns, respectively.
Example two
As shown in fig. 3, the NR-type power inductor structure of this embodiment includes an i-shaped magnetic core 1, a flat coil or a circular coil 2 wound around a core center post 11 of the i-shaped magnetic core 1, a magnetic plastic package layer (not shown) covering the i-shaped magnetic core 1 and the flat coil or the circular coil 2, and two electrodes (31, 32) connected to two terminals of the flat coil or the circular coil 2, where the two electrodes (31, 32) are exposed outside the magnetic plastic package layer.
The flat coil 2 is preferably used as the winding coil, the width direction of the flat wire of the flat coil 2 is perpendicular to the axial direction of the magnetic core center pillar 11, and the flat wire 2 is stacked layer upon layer in the axial direction of the magnetic core center pillar 11. The arrangement has better electrical performance and is more convenient for processing and layout of related components.
Further preferably, the NR-type power inductor is designed by the optimal design method according to any one of the technical solutions of the embodiments.
The foregoing is a more detailed description of the invention in connection with specific preferred embodiments and it is not intended that the invention be limited to these specific details. For those skilled in the art to which the invention pertains, several equivalent substitutions or obvious modifications can be made without departing from the spirit of the invention, and all the properties or uses are considered to be within the scope of the invention.
Claims (10)
1. An NR type power inductance structure optimization design method based on finite element simulation is characterized by comprising the following steps:
a. selecting a magnetic core material according to a design target, and preliminarily determining the number of winding turns, the size of a center pillar of the magnetic core, the wire diameter of a lead and DCR parameters;
b. b, carrying out parametric modeling in Maxwell on the basis of the parameters obtained in the step a to obtain a simulation model;
c. introducing the B-H curve of the magnetic core material into the simulation model, and carrying out finite element simulation by taking the saturation current of the NR type power inductor as a research object to obtain an L-I curve;
d. adjusting the number of turns of the winding wire in the step a for more than two times, and repeating the step b and the step c to obtain an L-I curve corresponding to each adjusted number of turns of the winding wire;
e. and d, comparing the L-I curves obtained in the step d, and determining an optimal structure.
2. The method as claimed in claim 1, wherein the parameters considered in selecting the magnetic core material in step a at least include voltage and operating frequency of the inductor in normal operating state, size and inductance of the NR power inductor product.
3. The method for optimally designing an NR-type power inductor structure based on finite element simulation as claimed in claim 1, wherein the design targets are: the voltage is 1V, the operating frequency is 1MHz, the inductance value is 1.0 muh, the size of the NR-type power inductor product is 2.5mm × 2.0mm × 1.2mm, and DCR is less than or equal to 0.025 Ω.
4. The finite element simulation-based NR-type power inductor structure optimization design method of claim 2, wherein the magnetic core material is carbonyl iron powder alloy.
5. The finite element simulation-based NR-type power inductor structure optimization design method of claim 1, wherein in the step d, the size of the core center pole is adjusted and simulated separately based on the number of winding turns in the step a and/or on the adjusted basis to obtain each corresponding L-I curve.
6. The finite element simulation-based NR type power inductor structure optimization design method of claim 5, wherein the size of the pillars in the core is adjusted to increase in sequence from 0.85mm as a starting point to 0.05mm in steps.
7. The finite element simulation-based NR-type power inductor structure optimization design method of claim 1, wherein the determining the optimal structure is: the design target is met, and the saturation current of the NR type power inductor is maximum.
8. The NR type power inductor is characterized in that the NR type power inductor structure comprises an I-shaped magnetic core, a flat coil or a round coil wound on a magnetic core center column of the I-shaped magnetic core, a magnetic plastic package layer covering the magnetic core and the flat coil or the round coil, and two electrodes connected with two leading-out ends of the flat coil or the round coil, wherein the two electrodes are exposed outside the magnetic plastic package layer.
9. The NR power inductor of claim 8, wherein a width direction of the flat wire of the flat coil is perpendicular to an axial direction of the core leg, and the flat wire is stacked one on another in the axial direction of the core leg.
10. The NR-type power inductor of claim 8 or 9, wherein the NR-type power inductor is designed by the optimum design method of any one of claims 1 to 7.
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| CN202110101901.XA CN112966405B (en) | 2021-01-26 | 2021-01-26 | NR type power inductor and optimization design method based on finite element simulation |
| PCT/CN2021/126257 WO2022028629A2 (en) | 2021-01-26 | 2021-10-26 | Nr-type power inductor and optimization design method based on finite element simulation |
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Cited By (3)
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| WO2022028629A3 (en) * | 2021-01-26 | 2022-03-17 | 深圳顺络电子股份有限公司 | Nr-type power inductor and optimization design method based on finite element simulation |
| CN114203428A (en) * | 2021-12-10 | 2022-03-18 | 乐庸一 | Manufacturing method of inductor with optional magnetic core configuration and injection molding inductor |
| WO2023041022A1 (en) * | 2021-09-17 | 2023-03-23 | Huawei Technologies Co., Ltd. | System and method for computer-assisted design of inductor for voltage-controlled oscillator |
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| CN114722689B (en) * | 2022-06-09 | 2022-09-20 | 淄博高新技术产业开发区Mems研究院 | MEMS cantilever beam device structure optimization method and device and computer equipment |
| CN115910518A (en) * | 2022-11-01 | 2023-04-04 | 浙江英洛华磁业有限公司 | Composite magnet assembly based on permanent magnet and electromagnet and assembly design method thereof |
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| WO2022028629A3 (en) | 2022-03-17 |
| CN112966405B (en) | 2023-04-14 |
| WO2022028629A2 (en) | 2022-02-10 |
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