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Iron Powder Core Inductor Design Software

Micrometals Inductor Design Software is a flexible user-friendly tool designed to supplement this catalog in the selection of iron powder cores for a variety of power conversion and line filter applications. The software is a DOS based program with a file size of 320 kB and is available at no charge. Copies of the disk can be obtained from the factory or through any of our sales representatives. The software can also be down loaded from the Software section of the website.

The main menu for the YEAR 2000 revision contains the following selections:

  1. DC Biased Inductors Design where the inductor must meet a given inductance at a DC current level with ripple conditions defined by voltage and frequency.
  2. Design of Controlled Swing inductors where the inductance does not exceed a maximum value at reduced current, but is otherwise similar to 1.)
  3. Design of Wide Swing inductors where the inductance at low current is typically 5 to 20 times higher than the inductance at maximum DC current. This application utilizes a ferrite/iron powder composite core as described on the Composite Core, Parts Listing page.
  4. Design of Active Power Factor Boost or buck inductors, commonly referred to as PFC chokes.
  5. Design of Power Line Frequency Inductors for differential-mode filtering using toroidal cores.
  6. Design of a Resonant Converter Inductor where the current is sinusoidal with no DC bias.
  7. Analyze a design of an inductor based on user defined parameters.
  8. Display Micrometals Catalog
  9. Wire Table

The design portion of the software accepts typical inputs such as required inductance, dc resistance, dc bias current, peak voltage, output voltage, and frequency. A single-layer or full winding can be specified. The user can select the preferred core geometry (i.e., Toroid, E-Core or Ferrite/Iron Powder Composite) and select specific core materials or all materials.

There are pre-set Design Constants and Limits which can be changed by the user. These parameters and their pre-set values follow:

Measurement Units System Mixed English
Wire Gage Standard American AWG
Ambient Temperature 25 °C
Maximum Temperature Rise 40
Minimum Copper Density 150 cir-mils/Amp
Maximum Window Fill Factor 40 percent
Minimum % Perm Under DC Bias 40 percent
Wire Resistivity Adjust Factor 1,000 dimensionless
Temp Rise Factor 1,000 C° mW/sq-cm
Temp Rise Characterisitic Exponent 0.833 dimensionless
Lead Length Allowance 2.5 inches each

The program will automatically calculate the smallest core size possible that will meet the specified needs and will display; 1) Micrometals Part Number, 2) Approximate unit price, 3) Core AL Value, 4) Required Number of Turns, 5) Wire Size, 6) Percent Window Fill, 7) DC Winding Resistance, 8) DC Magnetizing Force, 9) Percent Initial Permeability, 10) Core Loss, 11) Copper Loss, and 12) Temperature Rise. The wound dimensions and weight of the copper wire can also be displayed.

The software allows the design engineer to quickly work up multiple design solutions based on user specified electrical requirements and be easily printed for hard copies. The use of pop-up menus and the ability to scroll backwards through the design solutions greatly enhances this revision.

An important new feature of the YEAR 2000 revision is that predicted changes in core temperature versus time and temperature can be graphically displayed for the designs. This feature will allow the design engineer to see if the design is capable of meeting a minimum life expectancy. The graph will display projected core temperature change out 100,000 hours.

The following are definitions of the units utilized by the design software:

Unit Description Defined
AL Inductance Rating nH/N2
Price U S Dollars Approx. Value*
RDC DC Resistance ohms
HDC Magnetizing Force oersteds
P FE Core Loss watts
P CU Copper Loss watts
T Rise Temperature Rise celsius degrees
*Approximate value at 5,000 piece quantity

Please contact the factory for technical support. Micrometals will gladly provide sample cores to assist in your evaluation.

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