44# π 2 kW ZVS Phase Shift Full Bridge from Infineon
SuperPowers for Electrical Engineers π¦Έπ»ββοΈ
π Hello Supergineers! Dr. Molina here! π¨βπ§
Welcome to Dr.Molina Newsletter, where I break down Magnetic designs for you every week, in 4 minutes.Β
Each engineer has his design method for magnetics, and all of them will put their egos upfront to show how good their method is. My advice; if you want to evolve as a professional, listen to others and learn from them.
In this edition, I have learned a lot from Infineon App Notes and Iβm using this work from Infineon. Iβm going to show you how to design in less than 30 minutes the 2 kW Phase Shift Full Bridge of Infineon.
Simulation Phase
You can ask me for the project file or build it yourself. I used our online simulator to design the circuit and the Frenetic Magnetic components to download their waveforms.
Build the circuit (5 min)
Simulate the circuit to find the operating point of 2 kW(5 min)
Download the waveforms of the transformer (<1min)
Include the Frenetic Inductor and remove the Frenetic Transformer and run the simulation again (<1min)
Download the waveforms of the output inductor (<1min)
Magnetic Design
Transformer
Here is the SImulation Link.
I uploaded the waveforms and instead of asking for suggestions, I used the same component Infineon has designed and described in the following picture.
Here is my interpretation of their design. (7 min)
And the mechanical section (<1min).
The simulation for the 2 kW operation point, shows a loss of 7,45W and a temperature increment of 37ΒΊC assuming natural cooling.
Output Inductor
There should be a mistake in this data because I ran the simulation and the DC losses for the specified wire are huge (Current density of 12 A/cm3). (5min)
In this case, Frenetic suggests an ETD39 with square wire. I would even use the Bourns or Wurth Electronic components, to avoid customization.
They also include the resonant choke in the specs, I would like to challenge you with that design. They proposed a Toroidal of 32 mm in diameter.
Would you be able to reduce the size of their proposal?
Looking forward to your responses!!
If you want to receive the Circuit Simulator file, write to me and I will send you via email.
Building relationships
π We live in a connected world, where everyone is looking for automation of processes.
The design of power magnetics is divided into different stages, and most of the calculations follow several steps to produce an output, and this is where Frenetic helps you to accelerate (80% of time reduction in each case).
However, getting a magnetic design is much more than having an output of the software. You need specialist engineers in manufacturing, mechanical, and testing to complete the process and we donΒ΄t want you to talk with a BOT.
For this reason, we invest in having a strong team of engineers, which mission is being your partner, and your support. We build relationships.
π Our technical support has been rated 9,5/10 in our last survey.
Have a nice week.
Dr. Molina
Last part of this self explanatory article on how Frenetic can help you in optimizing the magnetics is key. When you invest in Frenetic you are not just acquiring SW to design magnetics but also the engagement with Frenetic teammates which will be there to support in your goals.