Example #8 Influence of the interleaving on the winding losses Designing a new 42-volt automotive power system requires knowledge of components, electronics and controls. It has become a truly multi-disciplinary engineering task. Ansoft's Electromechanical System Design Suite is a powerful combination of software simulation technology including electromagnetics, circuits, block diagrams, state machines, and specialized design programs which allow an engineer to successfully design and analyze a complete 42V system from start to finish.

Open PExprt application This example will show how changing the interleaving of windings can affect the winding losses.

Select File/New for a new project Select “Waveform Based” transformer component from the list of components and click on “OK” button

Select Ferroxcube library for design Drag the Ferroxcube library from the “Stock Library” and drop it on the “Design Library” to assign it

Define the required converter parameters Turns Ratio: 1:2 Switching Frequency: 150 kHz Power: 100 W Rest of parameters: default ones

Rest of parameters: default ones Define the Design Inputs Select “1D completely-full layers” winding strategy in order to generate 1D designs Rest of parameters: default ones

Start the design process Use “Calculations/Start Design Process” or click on the button at the toolbar

Allow PExprt selecting the core, wires and core materials Click on “Yes” button

Save the project after the design process Designing the component… Save the project after the design process

Remove all the designs of the list except the fourth one You have to delete all the designs in the list of results except the fourth one (the one highlighted in the list below)

Remove all the designs of the list except the fourth one Deleting designs 1. Select the design clicking on it 2. Right mouse button click (or use “delete” key in the keyboard) 3. Select “Delete” in the pup-up menu

After deleting the designs, only the last one should be in the list Only one design left in the list of results After deleting the designs, only the last one should be in the list

Creating copies of the design Create two copies of the design Creating copies of the design 1. Select the design clicking on it 2. Right mouse button click 3. Select “Create a Copy” in the pup-up menu Repeat steps 2 and 3 to create a second copy Save the component

Select the first design in the list Selecting the design to be modified Select the first design in the list

Select “Open PExprt Modeler [PEmag]” Modifying the winding strategy of the designs Use “Modeler/Generate Model” menu or click on the button at the toolbar Select “Open PExprt Modeler [PEmag]” Click on “OK”

Modifying the winding strategy of the designs PExprt Modeler Widow

Modifying the winding strategy of the designs Select “Connections/Remove” menu item Remove all the connections clicking on the connection ends

Modifying the winding strategy of the designs Select “Connections/Add” menu item Create primary winding (winding A) using the layer at the middle Create secondary winding (winding B) using the other layers

Generating the Analytical based model (based on transmission lines) Select “Modeler/Analytical Modeler (1D)/Start 1D model generation” or use the tool bar button

Click on “Model + Values” Generating Analytical based models of the designs Click on “Model + Values”

Exit the PExprt Modeler application Modifying the winding strategy of the designs Save the component Do not delete the model Exit the PExprt Modeler application

Select the second design in the list Generating FEA based models of the designs Select the second design in the list

Generating FEA based models of the designs Use “Modeler/Generate Model” menu or click on the button at the toolbar Select “Analytical Model” in order to generate the transmission line base model Click on “OK”

Select “NO” in order to use the 1D models previously generated Recalculating winding losses with the previously generated models Use “Calculations/Recalculate Winding Losses” menu or click on the button at the toolbar Select “NO” in order to use the 1D models previously generated

Explore results This design was the original one. The coupling between the windings is not considered Winding losses have been recalculated using the models The icon is modified in order to notify that the winding losses of these designs have been recalculated with the 1D (transmission line based) model. The coupling between the windings is considered

Explore results Each design can be explored in detail For example, select the second design

Explore the performance results Explore results Explore the performance results

Explore the constructive results Explore results Explore the constructive results

Explore results: Comparing results