WO2022028629A2 - 一种nr型功率电感及基于有限元仿真的优化设计方法 - Google Patents

一种nr型功率电感及基于有限元仿真的优化设计方法 Download PDF

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WO2022028629A2
WO2022028629A2 PCT/CN2021/126257 CN2021126257W WO2022028629A2 WO 2022028629 A2 WO2022028629 A2 WO 2022028629A2 CN 2021126257 W CN2021126257 W CN 2021126257W WO 2022028629 A2 WO2022028629 A2 WO 2022028629A2
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type power
power inductor
magnetic core
finite element
element simulation
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WO2022028629A3 (zh
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叶小莉
吴蕾
吴锦超
欧阳过
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深圳顺络电子股份有限公司
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    • G—PHYSICS
    • G06—COMPUTING; CALCULATING OR COUNTING
    • G06F—ELECTRIC DIGITAL DATA PROCESSING
    • G06F30/00—Computer-aided design [CAD]
    • G06F30/20—Design optimisation, verification or simulation
    • G06F30/23—Design optimisation, verification or simulation using finite element methods [FEM] or finite difference methods [FDM]

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  • 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.
  • high-current inductors With the demand for high frequency, miniaturized high-current inductors are gradually applied to 5G base stations, industrial control motherboards, notebook computers, automotive equipment, distribution power systems, DC/DC converters, LED drive power supplies, communication equipment, medical equipment, military industry Electronics, aerospace technology and other fields.
  • the specific requirements of high-current inductors are small size, high current, and good temperature rise current and saturation current in high frequency and high temperature environments.
  • NR-type inductors the most prominent problem is the design conflict between low DCR (Direct Current Resistance) and high saturation current.
  • the winding space is limited, and low DCR and high saturation current are mutually restricted.
  • the cross-sectional area of the NR-type magnetic core blades and the central column should be kept as much as possible. balance.
  • this traditional structural design principle leads to the reduction of the inductor winding space and the lack of effective use of space, resulting in the inductance products unable to meet the required inductance characteristics, such as: L value (inductance value), DCR,
  • the saturation current will affect each other. For example, when a high saturation current is required, the center column needs to be designed in a large size.
  • the cross-sectional area of the center column and the cross-sectional area of the magnetic core blade need to be balanced, so the blade is thickened and the wire is wound. The space is reduced. At this time, to achieve the corresponding inductance, the copper wire diameter can only be selected with a small wire diameter, and the DCR will be large. As mentioned above, the DCRs are contradictory. When the saturation current is small, the DCR may be large; when the DCR is large, the saturation current may be small. Because the mutual influence size and influence direction cannot be determined in advance, the traditional design method cannot solve the design contradiction.
  • the present invention provides a method for optimizing the structure of NR type power inductors based on finite element simulation, comprising the following steps:
  • step b Based on the parameters obtained in step a, perform parametric modeling in Maxwell to obtain a simulation model
  • step d Adjust the number of turns of the winding in the step a more than twice, repeat the step b and the step c, and obtain the L-I curve corresponding to each adjusted number of the winding turns;
  • the present invention can also adopt the following optional scheme:
  • the parameters considered when selecting the magnetic core material in the step a include at least the voltage and operating frequency of the inductor under normal working conditions, the size and inductance value of the NR type power inductor product.
  • the magnetic core material is carbonyl iron powder alloy.
  • the size of the center column of the magnetic core is adjusted on the basis of the number of turns of the winding and/or after adjustment in the step a, and simulation is performed respectively to obtain each corresponding LI. curve.
  • the size of the central column of the magnetic core is adjusted to start at 0.85mm and increase in steps of 0.05mm.
  • the optimal structure is determined as follows: the design objective is met, and the saturation current of the NR type power inductor is the largest.
  • the present invention also provides an NR type power inductor.
  • the NR type power inductor structure includes an I-shaped magnetic core, a flat coil or a circular coil wound on the central column of the magnetic core of the I-shaped magnetic core, and a coil covered on the I-shaped magnetic core.
  • the magnetic core and the magnetic plastic sealing layer on the flat coil or the circular coil, two electrodes connected to the two lead ends of the flat coil or the circular coil, and the two electrodes are exposed outside the magnetic plastic sealing layer .
  • the width direction of the flat wires of the flat coil is perpendicular to the axial direction of the central column of the magnetic core, and the flat wires are stacked on top of the axial direction of the central column of the magnetic core.
  • the NR type power inductor is designed and obtained by the optimization design method described in any one of the above.
  • FIG. 1 is a flowchart of a method for optimizing the structure of an NR-type power inductor based on finite element simulation according to an embodiment of the present invention.
  • FIG. 2 is an L-I curve diagram in an optimized design of an embodiment, which includes three L-I curves corresponding to three different winding structures.
  • FIG. 3 is a schematic cross-sectional view of an inductor winding structure according to an embodiment.
  • NR inductors are also called automatic shielding inductors because they are made by fully automated machines. Japan's Taiyo Yuden first launched this product, so many people are used to calling them NR inductors (the number of Taiyu).
  • the saturation current as the research object means that the current Isat is used as the main electrical characterization index to change the structure and optimize the design of the NR type power inductor structure.
  • Saturation Current is usually expressed by "Isat”, and Japanese companies also commonly use DCI1.
  • the unit of saturation current is ampere, which is expressed in "A”. Generally, it refers to the current value when the L value drops by 30%.
  • the blade will not become a limitation due to the excessively large cross-sectional area of the central column, so the device saturation current is used as the research object to solve the blindness problem in the selection of the central column structure after the inductor blade is preferentially saturated, thereby
  • the structure of the inductor and the number of winding turns can be determined in a short period of time, and the problem of optimal design of high-current magnetic components is finally solved.
  • the optimal design method of the present invention is summarized in the flow chart shown in Figure 1 for understanding, specifically:
  • Input electrical requirements such as the voltage and operating frequency of the inductor under normal working conditions, determine the product size, inductance value, etc.
  • An NR-type power inductor structure optimization design method based on finite element simulation comprising the following steps:
  • step b Based on the parameters obtained in step a, perform parametric modeling in Maxwell to obtain a simulation model
  • step d Adjust the number of turns of the winding in the step a more than twice, repeat the step b and the step c, and obtain the L-I curve corresponding to each adjusted number of the winding turns;
  • the magnetic core material is a carbonyl iron powder alloy
  • the optimal structure is determined by considering the following two conditions at the same time: the first is to meet the design objective, and the second is that the saturation current of the NR type power inductor is the largest.
  • the size of the center column of the magnetic core is adjusted on the basis of the number of turns of the winding and/or after adjustment in the step a, and simulations are performed respectively to obtain each Corresponding LI curves.
  • the size of the central column of the magnetic core is adjusted to start at 0.85mm and increase in steps of 0.05mm. Then, draw L-I curves of different central column structures, and select the magnetic core structure design with the optimal saturation current according to each of the L-I curves, which is the target NR type power inductor structure design of this embodiment.
  • 6.5T, 7.5T and 8.5T in the figure represent that the winding turns are 6.5 turns, 7.5 turns and 8.5 turns, respectively.
  • the NR type power inductor structure of the present embodiment includes an I-shaped magnetic core 1 , a flat coil or a circular coil 2 wound on the core column 11 of the I-shaped magnetic core 1 , and a covering The magnetic plastic encapsulation layer (not shown in the figure) on the I-shaped magnetic core 1 and the flat coil or circular coil 2, and two electrodes ( 31, 32), the two electrodes (31, 32) are exposed outside the magnetic plastic sealing layer.
  • the flat coil 2 is preferably used for the winding coil, and the width direction of the flat wire of the flat coil 2 is perpendicular to the axial direction of the central column 11 of the magnetic core, and the flat wire 2 is in the magnetic core.
  • the axial directions of the columns 11 are stacked on top of each other. This arrangement has better electrical performance and is more convenient for processing and layout of related components.
  • the NR type power inductor is designed and obtained by the optimized design method described in any one of the technical solutions in the first embodiment.

Abstract

本发明公开了一种NR型功率电感及基于有限元仿真的优化设计方法，所述优化设计方法包括：a.根据设计目标选择磁芯材料，并初步确定绕线匝数，磁芯中柱尺寸，导线线径，DCR参数；b.在Maxwell中进行参数化建模，得到仿真模型；c.以所述NR型功率电感的饱和电流为研究对象，进行有限元仿真，得到L-I曲线；d.调整参数并重复所述步骤b和c，得到多个相应的L-I曲线；e.比较并确定最优结构。在有限元仿真中，以NR型功率电感的饱和电流为研究对象，可以更加准确并快速得到NR型功率电感在直流电阻最小的情况下，不同中柱尺寸下的电感及饱和电流变化，从而得到最优的结构设计方案。

Description

一种NR型功率电感及基于有限元仿真的优化设计方法 技术领域
本发明涉及磁性元器件的设计技术领域，尤其涉及一种基于有限元仿真的NR型功率电感结构优化设计方法。
背景技术
随着高频化的需求，小型化大电流电感逐渐被应用于5G基站、工控主板、笔记本电脑、车载设备、分配电源系统、DC/DC转换器、LED驱动电源、通讯设备、医疗设备、军工电子、航天科技等领域。大电流电感的具体要求是小体积、大电流，在高频和高温环境下仍保持良好的温升电流及饱和电流。对于NR型电感而言，最突出的问题就是低DCR(Direct Current Resistance，直流电阻)和高饱和电流的设计矛盾问题。
在电感设计中，因材料及尺寸的限制，绕线空间有限，低DCR和高饱和电流是相互制约的，对于传统的磁芯结构设计原则，NR型磁芯叶片及中柱截面积尽可能保持平衡。在大电流电感的结构设计时，这种传统的结构设计原则导致电感绕线空间减小，有效利用空间不足，造成电感产品无法达到要求的电感特性，比如：L值(电感值)、DCR、饱和电流会相互影响，例如：要求高饱和电流时，中柱需要往大尺寸设计，在传统结构设计原则中，中柱截面积和磁芯叶片截面积需要保持平衡，所以叶片加厚，绕线空间减小，这时，要达到相应电感量，铜线线径只能选取小线径，DCR就会大。如上所述DCR相互矛盾，饱和电流小，DCR可能会大；DCR大时，饱和电流可能就小。因为相互之间的影响大小及影响方向等均不能提前确定，所以传统的设计方法无法解决该设计矛盾问题。
以上背景技术内容的公开仅用于辅助理解本申请的发明构思及技术方案，其并不必然属于本申请的现有技术，在没有明确的证据表明上述内容在本申请的申请日已经公开的情况下，上述背景技术不应当用于评价本申请的新颖性和创造性。
发明内容
为克服前述现有技术无法解决NR型功率电感结构设计存在的设计矛盾问 题，本发明提供一种基于有限元仿真的NR型功率电感结构优化设计方法，包括如下步骤：
a.根据设计目标选择磁芯材料，并初步确定绕线匝数，磁芯中柱尺寸，导线线径，DCR参数；
b.以步骤a得到的参数为基础，在Maxwell中进行参数化建模，得到仿真模型；
c.将所述磁芯材料的B-H曲线导入所述仿真模型中，以所述NR型功率电感的饱和电流为研究对象，进行有限元仿真，得到L-I曲线；
d.调整所述步骤a中的所述绕线匝数两次以上，重复所述步骤b和所述步骤c，得到对应各个调整后的所述绕线匝数的L-I曲线；
e.比较所述步骤d中得到的各个所述L-I曲线，并确定最优结构。
本发明还可采用如下可选方案：
所述步骤a中选择磁芯材料时的考虑参数至少包括电感正常工作状态下的电压及工作频率，NR型功率电感产品的尺寸和电感值。
所述步骤a中的所述设计目标为：所述工作频率为1MHz，所述电压为1V，所述电感值为L＝1.0μH，所述NR型功率电感产品的尺寸为长×宽×高＝2.5mm×2.0mm×1.2mm，DCR≤0.025Ω。
所述磁芯材料为羰基铁粉合金。
所述步骤d中，还在所述步骤a中的所述绕线匝数基础上和/或调整后的基础上，调整所述磁芯中柱的尺寸并分别进行仿真，得到各个相应的L-I曲线。
调整所述磁芯中柱的尺寸以0.85mm为起点，按照步进为0.05mm依次增大。
所述确定最优结构为：满足所述设计目标，且所述NR型功率电感的饱和电流最大。
本发明还提供一种NR型功率电感，所述NR型功率电感结构包括，工字形磁芯，卷绕在所述工字形磁芯的磁芯中柱上的扁平线圈或圆线圈，以及覆盖于所述磁芯及所述扁平线圈或圆线圈上的磁性塑封层，与所述扁平线圈或圆线圈的两个引出端相连的两个电极，所述两个电极暴露在所述磁性塑封层外。
优选的，所述扁平线圈的扁平线的宽度方向垂直于所述磁芯中柱的轴向，且所述扁平线在所述磁芯中柱的轴向上层层叠置。
再优选的，所述NR型功率电感通过上文任一项所述的优化设计方法设计得到。
本发明与现有技术相比的有益效果至少包括：
在有限元仿真中，以NR型功率电感的饱和电流为研究对象，可以更加准确并快速得到NR型功率电感在直流电阻最小的情况下，不同中柱尺寸下的电感及饱和电流变化，从而得到最优的结构设计方案。
附图说明
图1是本发明一个实施例的基于有限元仿真的NR型功率电感结构优化设计方法流程图。
图2是一个实施例的优化设计中的L-I曲线图，其中包括三个不同的绕组结构对应的三个L-I曲线。
图3是一个实施例的电感器绕组结构剖视示意图。
具体实施方式
下面结合具体实施方式并对照附图对本实用新型做进一步详细说明。其中相同的附图标记表示相同的部件，除非另外特别说明。应该强调的是，下述说明仅仅是示例性的，而不是为了限制本发明的范围及其应用。
相关技术术语说明/定义：
NR电感，由于其使用全自动化机器制作，所以又称为自动化屏蔽电感，日本太阳诱电首先推出了该产品，所以很多人又习惯称为NR电感(太诱的编号)。
以饱和电流为研究对象，是指以电流Isat为主要电性表征指标，进行结构的变化和对NR型功率电感结构进行优化设计。饱和电流(Saturation Current)通常用“Isat”来表示，日系企业也常用DCI1表示。按照国际标准单位制，饱和电流单位为安培，采用“A”表示。一般是指L值下降30％时的电流值。
以下是本发明的相关构思的分析说明。
以往的设计观念认为，叶片和中柱截面积相等才能保持电感器件的有效利用率更高。因此，在设计时，若中柱截面积＝叶片截面积时，就认为结构为最优。但发明人发现，中柱截面积增加后，叶片也需要加厚，导致绕线空间减小，这样中柱的大小就无法确定，因此并不能够获得最优的结构设计。经发明人进一步研究发现，叶片不会因为中柱截面积过大而成为限制，所以采用以器件饱和电流为 研究对象，解决电感器叶片优先饱和后，中柱结构选择上的盲目性问题，从而可以在较短的时间周期内确定电感器结构及绕组圈数，并最终解决了大电流磁性元器件的优化设计问题。本发明的优化设计方法如图1所示的流程图进行概括，以便理解，具体是：
输入电性要求，如电感正常工作状态下的电压及工作频率，确定产品尺寸、电感值等；
通过推算表调参，并输出DCR；
得到磁芯结构、线径、圈数(匝数)等；
建模后代入MAXWELL仿真模型中，同时输入μe和磁芯B-H曲线，进行有限元仿真；
仿真后输出L值(绕线电感产品或涂胶电感产品的电感值)、L-I数据；
判断L值、L-I数据是否达到规格，即选出满足要求设计且对应饱和电流最大者，即为最优结构；
如是，输出方案；如否，返回至“通过推算表调参，并输出DCR”步骤，重复操作，直到L值、L-I数据达到规格，结束。
实施例一
一种基于有限元仿真的NR型功率电感结构优化设计方法，包括如下步骤：
a.根据设计目标选择磁芯材料，并初步确定绕线匝数，磁芯中柱尺寸，导线线径，DCR参数；
b.以步骤a得到的参数为基础，在Maxwell中进行参数化建模，得到仿真模型；
c.将所述磁芯材料的B-H曲线导入所述仿真模型中，以所述NR型功率电感的饱和电流为研究对象，进行有限元仿真，得到L-I曲线；
d.调整所述步骤a中的所述绕线匝数两次以上，重复所述步骤b和所述步骤c，得到对应各个调整后的所述绕线匝数的L-I曲线；
e.比较所述步骤d中得到的各个所述L-I曲线，并确定最优结构。
本实施例中，所述磁芯材料为羰基铁粉合金；所述步骤a中的所述设计目标为：所述工作频率为1MHz，所述电压为1V，所述电感值为L＝1.0μH，所述NR型功率电感产品的尺寸为长×宽×高＝2.5mm×2.0mm×1.2mm，DCR≤0.025 Ω。
所述确定最优结构为同时考虑以下两个条件：首先是满足所述设计目标，其次是所述NR型功率电感的饱和电流最大。
作为优选，所述步骤d中，还在所述步骤a中的所述绕线匝数基础上和/或调整后的基础上，调整所述磁芯中柱的尺寸并分别进行仿真，得到各个相应的L-I曲线。调整所述磁芯中柱的尺寸以0.85mm为起点，按照步进为0.05mm依次增大。然后，绘制出不同中柱结构的L-I曲线，并根据各个所述L-I曲线选择饱和电流最优的磁芯结构设计，即为本实施例的目标NR型功率电感结构设计。如图2所示的L-I曲线图，可见，在满足前述设计目标的前提下，中间一个L-I曲线中自右向左数第二个圆点(Iset＝5A，L＝1μH)对应的NR型功率电感结构为最优。图中的6.5T、7.5T和8.5T分别代表所述绕线匝数为6.5圈、7.5圈和8.5圈。
实施例二
如图3所示，本实施例的NR型功率电感结构包括，工字形磁芯1，卷绕在所述工字形磁芯1的磁芯中柱11上的扁平线圈或圆线圈2，以及覆盖于所述工字形磁芯1及所述扁平线圈或圆线圈2上的磁性塑封层(图中未示出)，与所述扁平线圈或圆线圈2的两个引出端相连的两个电极(31、32)，所述两个电极(31、32)暴露在所述磁性塑封层外。
其中，卷绕线圈优选采用所述扁平线圈2，且所述扁平线圈2的扁平线的宽度方向垂直于所述磁芯中柱11的轴向，且所述扁平线2在所述磁芯中柱11的轴向上层层叠置。该设置方式具有更好的电性能，且更方便加工和相关部件的布局。
进一步优选的，所述NR型功率电感通过实施例一任一技术方案所述的优化设计方法设计得到。
以上内容是结合具体的优选实施方式对本发明所作的进一步详细说明，不能认定本发明的具体实施只局限于这些说明。对于本发明所属技术领域的技术人员来说，在不脱离本发明构思的前提下，还可以做出若干等同替代或明显变型，而且性能或用途相同，都应当视为属于本发明的保护范围。

Claims (10)

  1. 一种基于有限元仿真的NR型功率电感结构优化设计方法，其特征在于包括如下步骤：
    a.根据设计目标选择磁芯材料，并初步确定绕线匝数，磁芯中柱尺寸，导线线径，DCR参数；
    b.以步骤a得到的参数为基础，在Maxwell中进行参数化建模，得到仿真模型；
    c.将所述磁芯材料的B-H曲线导入所述仿真模型中，以所述NR型功率电感的饱和电流为研究对象，进行有限元仿真，得到L-I曲线；
    d.调整所述步骤a中的所述绕线匝数两次以上，重复所述步骤b和所述步骤c，得到对应各个调整后的所述绕线匝数的L-I曲线；
    e.比较所述步骤d中得到的各个所述L-I曲线，并确定最优结构。
  2. 如权利要求1所述的基于有限元仿真的NR型功率电感结构优化设计方法，其特征在于，所述步骤a中选择磁芯材料时的考虑参数至少包括电感正常工作状态下的电压及工作频率，NR型功率电感产品的尺寸和电感值。
  3. 如权利要求1所述的基于有限元仿真的NR型功率电感结构优化设计方法，其特征在于，所述设计目标为：所述电压为1V，所述工作频率为1MHz，所述电感值为L＝1.0μH，所述NR型功率电感产品的尺寸为长×宽×高＝2.5mm×2.0mm×1.2mm，DCR≤0.025Ω。
  4. 如权利要求2所述的基于有限元仿真的NR型功率电感结构优化设计方法，其特征在于，所述磁芯材料为羰基铁粉合金。
  5. 如权利要求1所述的基于有限元仿真的NR型功率电感结构优化设计方法，其特征在于，所述步骤d中，还在所述步骤a中的所述绕线匝数基础上和/或调整后的基础上，调整所述磁芯中柱的尺寸并分别进行仿真，得到各个相应的L-I曲线。
  6. 如权利要求5所述的基于有限元仿真的NR型功率电感结构优化设计方法，其特征在于，调整所述磁芯中柱的尺寸以0.85mm为起点，按照步进为0.05mm依次增大。
  7. 如权利要求1所述的基于有限元仿真的NR型功率电感结构优化设计方法，其特征在于，所述确定最优结构为：满足所述设计目标，且所述NR型功率 电感的饱和电流最大。
  8. 一种NR型功率电感，其特征在于，所述NR型功率电感结构包括，工字形磁芯，卷绕在所述工字形磁芯的磁芯中柱上的扁平线圈或圆线圈，以及覆盖于所述磁芯及所述扁平线圈或圆线圈上的磁性塑封层，与所述扁平线圈或圆线圈的两个引出端相连的两个电极，所述两个电极暴露在所述磁性塑封层外。
  9. 如权利要求8所述的NR型功率电感，其特征在于，所述扁平线圈的扁平线的宽度方向垂直于所述磁芯中柱的轴向，且所述扁平线在所述磁芯中柱的轴向上层层叠置。
  10. 如权利要求8或9所述的NR型功率电感，其特征在于，所述NR型功率电感通过如权利要求1-7任一项所述的优化设计方法设计得到。
PCT/CN2021/126257 2021-01-26 2021-10-26 一种nr型功率电感及基于有限元仿真的优化设计方法 WO2022028629A2 (zh)

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