Transforming the Future of Power Electronics Planar Transformers & Inductors.

Transcription

1 Transforming the Future of Power Electronics Planar Transformers & Inductors

2 Company Profile Himag Planar Ltd. has pioneered planar transformer technology from the UK since 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 Planar Transformers 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 highfrequency 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. 1

3 Planar Transformers Planar 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 High Efficiency (>99%) Low profile (<40mm height) Lightweight (5g per 100W) Low Leakage Inductance Repeatability (Controlled Parasitics) Customised Terminations Highly Efficient Cooling Multiple Multiple Winding Options Dimensional Accuracy 4kV Isolation, typical Reduced EMI Applications 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 2

4 Product Range Overview Transformers Planar Transformers / PAGE SIZE 130 1kW MAX 3MHz MAX 500V MAX 100A MAX 4 SIZE kW MAX 3MHz MAX 500V MAX 120A MAX 5 SIZE 225 2kW MAX 3MHz MAX 600V MAX 150A MAX 6 SIZE 230 2kW MAX 3MHz MAX 500V MAX 200A MAX 7 SIZE 310 5kW MAX 3MHz MAX 600V MAX 400A MAX 8 SIZE kW MAX 3MHz MAX 750V MAX 300A MAX 9 SIZE kW MAX 2MHz MAX 1000V MAX 500A MAX 10 SIZE kW MAX 2MHz MAX 1000V MAX 300A MAX 11 SIZE kW MAX 1MHz MAX 1000V MAX 750A MAX 12 SIZE kW MAX 1MHz MAX 1000V MAX 1000A MAX 13 SIZE kW MAX 1MHz MAX 1000V MAX 1200A MAX 14 SIZE kW MAX 1MHz MAX 1000V MAX 1200A MAX 15 SIZE kW MAX 1MHz MAX 1000V MAX 1200A MAX 16 Inductors Size: 130 Size: 195 Size: 225 Size: 230 Size: 310 Size: 350 Size: 500 Size: 540 Size: 560 Size: 1080 Size: 1200 Size: 2400 Size:

5 SIZE 130 1kW MAX 1kW MAX 500V MAX 3MHz MAX 500V MAX 100A MAX CUSTOM CUSTOM 175W 253W 729W 100V - 300V 20V - 30V 300V - 400V 100kHz 250kHz 150kHz 350V 230V 27V 0.5A 1.1A 27A 11:38 1:20 32:7 4kVrms 20kHz-3MHz 45g (typ.) 4

6 SIZE kW MAX 1.5kW MAX 500V MAX 3MHz MAX 500V MAX 120A MAX CUSTOM CUSTOM 420W 800W 1.1kW 20V - 40V 10V - 18V 90V 125kHz 100kHz 250kHz 28V 400V 28V 15A 2A 40A 2:6 2:88 5:2 4kVrms 20kHz-3MHz 85g (typ.) 5

7 SIZE 225 2kW MAX 2kW MAX 600V MAX 3MHz MAX 600V MAX 150A MAX CUSTOM CUSTOM 1kW 2kW 2kW 100V - 200V 300V - 400V 375V - 480V 75kHz 100kHz 250kHz 40V 180V 420V 25.0A 8.30A 4.75A 5:2 8:5 5:7 4kVrms 20kHz-3MHz 110g (typ.) 6

8 SIZE 230 2kW MAX 2kW MAX 500V MAX 3MHz MAX 500V MAX 200A MAX CUSTOM CUSTOM 400W 1.4kW 1.5kW 12V 24V 60V - 90V 350V - 420V 60kHz 100kHz 75kHz 300V 14V 48V 1.3A 100A 30A 2:50 4:2 21:3 4kVrms 20kHz-3MHz 130g (typ.) 7

9 SIZE 310 5kW MAX 5kW MAX 600V MAX 3MHz MAX 600V MAX 400A MAX CUSTOM CUSTOM 2.4kW 3.6kW 4kW 300V - 400V 100V - 150V 400V 100kHz 200kHz 50kHz 12V 300V 500V 200A 12A 8A 18:1 3:9 21:26 4kVrms 20kHz-3MHz 300g (typ.) 8

10 SIZE kW MAX 6.5kW MAX 750V MAX 3MHz MAX 750V MAX 300A MAX CUSTOM CUSTOM 570W 1.8kW 4.8kW 36V 200V - 500V 130V - 150V 100kHz 100kHz 75kHz 190V 18V 24V 3A 100A 200A 4: :1 4:2 4kVrms 20kHz-3MHz 200g (typ.) 9

11 SIZE kW MAX 10kW MAX 1000V MAX 2MHz MAX 1000V MAX 500A MAX CUSTOM CUSTOM 3.5kW 5.4kW 9kW 420V - 622V 350V - 375V 780V - 800V 100kHz 75kHz 130kHz 29V 120V 350V 120A 45A 25A 12:1+1 10:4 16:8 4kVrms 20kHz-3MHz 400g (typ.) 10

12 SIZE kW MAX 70mm MIN 108mm MAX 18mm MIN 45mm MAX 64mm MAX 10kW MAX 1000V MAX 2MHz MAX 800V MAX 300A MAX CUSTOM CUSTOM 3.0kW 6.0kW 10kW 400V - 600V 550V - 800V 600V - 800V 50kHz 100kHz 200kHz 40V 200V 100V 75A 30A 100A 9:1 5:2 7:1+1 Size 510 4kVrms 20kHz-3MHz 430g (typ.) 11

13 SIZE kW MAX 112mm MIN 135mm MAX 22mm MIN 48mm MAX 102mm MAX 15kW MAX 1000V MAX 1MHz MAX 1000V MAX 750A MAX CUSTOM CUSTOM 9kW 10kW 13.5kW 450V - 650V 520V - 750V 375V - 425V 100kHz 50kHz 60kHz 250V 400V 225V 37A 25A 60A 16:6 14:12 12:8 5.5kVrms 2.75kVrms 2.75kVrms 20kHz-1MHz 1kg (typ.) 12

14 SIZE kW MAX 219MM MAX 135MM MAX INC. HEATSINK 58MM MAX POSS. MIN DIMENSIONS 194MM X 102MM X 22.5MM 30kW MAX 1000V MAX 1MHz MAX 1000V MAX 1000A MAX CUSTOM CUSTOM 15kW 17kW 30kW 583V - 745V 400V - 800V 540V - 700V 75kHz 45kHz 100kHz 65V 200V 350V 230A 85A 90A 9:1 16:8 16: kVrms 2.75kVrms 2.75kVrms 20kHz-1MHz 2kg (typ.) 13

15 SIZE kW MAX 177mm MIN 237mm MAX 40mm MIN 62mm MAX 153mm MAX 50kW MAX 1000V MAX 1MHz MAX 1000V MAX 1200A MAX CUSTOM CUSTOM 15kW 25kW 50kW 500V - 800V 850V V 800V V 75kHz 100kHz 200kHz 40V 350V 200V 375A 72A 250A 12:1+1 12:5 5:1 5.5kVrms 2.75kVrms 2.75kVrms 20kHz-3MHz 1.5kg (typ.) 14

16 SIZE kW MAX 293mm 40mm MIN 62mm MAX 153mm MAX 80kW MAX 1000V MAX 1MHz MAX 1000V MAX 1200A MAX CUSTOM CUSTOM 80kW 650V 20kHz 400V 200A 13:10 Size kVrms 2.75kVrms 2.75kVrms 20kHz-3MHz 5kg (typ.) 15

17 SIZE kW MAX 348mm 40mm MIN 62mm MAX 153mm MAX 120kW MAX 1000V MAX 1MHz MAX 1000V MAX 1200A MAX CUSTOM CUSTOM 120kW V 20kHz 685V 175A 15:13 Size kVrms 2.75kVrms 2.75kVrms 20kHz-3MHz 10kg (typ.) 16

18 Auxiliary-Power Range 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: Size A 35W RANGE FREQ RANGE TOPOLOGY INSULATION TEMP. 10W - 35W PSU Output 1 2A 50kHz Flyback 5kV C 250V - 900V PSU Output 2 & 3 0.2A PSU Output A Size B 55W RANGE FREQ RANGE TOPOLOGY INSULATION TEMP. 20W - 55W PSU Output 1 2A 50kHz Flyback 5kV C 250V - 900V PSU Output 2 & A PSU Output 4 1.5A Custom Auxiliary Planar Transformers 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. RANGE FREQ RANGE TOPOLOGY INSULATION TEMP. 10W - 55W 50kHz Flyback 5kV C 250V - 900V PSU Output 1 PSU Output 2 & 3 PSU Output 4 PSU Output 5 PSU Output 6 to A 0.2A 0.75A 0.1A 0.25A 17

19 Terminations Himag 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. Multi-Pin PCB Mounting Bolted Connections Power Soldered Leads Horizontal PCB Mounting Customised Extended Lead-Frames Fly Leads Vertical PCB Mounting Bolted and Soldered Connections Vertical PCB to PCB Heatsinks 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. 18

20 Quality 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 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. 19

21 Custom Design Himag 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 Converter The 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 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. 20

22 Integrated Magnetics Where 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 60Adc. Retro Fit Non-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 leadframe/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 / Flexibility High 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. 21

23 Contact Us Headquarters Himag Planar Magnetics Ltd. Unit A, The Aquarius Centre, Edison Close, Waterwells Business Park, Quedgeley, Glos. GL2 2FN United Kingdom Tel: +44 (0) Fax: +44 (0)

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