交換式電源供應器之功率因數修正電感器的研究與應用

Application and Study of Magnetic Components for PFC Inductor of SMPS

卓景暉(Ching-Hui Cho)

指導教授 ： 許世哲

中原大學/電機資訊學院/電機工程研究所/碩士(2017年)

https://doi.org/10.6840/cycu201700626

摘要

本報告主要敘述磁性元件應用於交換式電源供應器的功率因數修正(PFC)電感器的研究與應用。隨著人類大量使用切換式電源轉換器的產品，環保節能成為產品開發的主要趨勢，其中電源供應器中的磁性元件在體積與整體損耗上占有相當重要的份量，因此本報告以PFC 電感器做為研究的對象。
電感器設計必須符合能量儲存需求及滿足損耗、空間、成本、EMI、溫度性能和可靠性等要求。本研究以磁性元件的鐵芯材質、種類和形狀為研究方向，首先介紹各種不同鐵芯材質的比較和應用，並進而探討電感器中鐵芯主要考量的參數如:有效截面積值(Ae)、有效磁路長度(Le)和繞線的銅窗面積(Wa)等，並參考規範IEC 60205標準找出適合的鐵芯尺寸、形狀與體積，用於本研究的PFC電感器。接著介紹銅線的種類與特性，並選用適合本電感器的扁平銅線所製作而成的扁平空心線圈，最後針對扁平空心線圈介紹其優點與特性。
由於大多數的功率電感需要手工繞線，PFC電感也不例外。本研究使用一可組裝線圈的EE型鐵芯取代環形 (Toroid) 鐵芯。EE型的鐵芯材質可混合使用鐵氧體和粉末鐵芯，其中的鐵芯參數包含Ae、Le等均為筆者自己設計與選用，並透過計算將效率與體積先行評估，且探討元件的銅損與鐵損的構成，來選擇適合的材質並搭配扁平線圈。其線圈製作的方式是以自動繞線機繞製完成，這可達成鐵芯與線圈自動組裝的目的。如此即可自動化生產，並有效提高電源的功率密度，減少勞動成本和提升工廠的生產效率，且提高電源供應器的空間利用率，是其最大優勢。

關鍵字

功率因數修正 ； 開關電源供應器 ； 扁平線圈 ； 功率因數修正電感器

並列摘要

This report focuses on the research and application of magnetic components in the power factor correction (PFC) inductor used in switching power supplies. With the large number of products using switching power converters, the concern of environmental protection and energy saving for these products is the main trend. The magnetic components in the power supply unit occupy a very important position in volume and overall power loss. That is why this report uses the PFC inductor as the research target.
When we design a PFC inductor, the inductor must meet the energy storage demand and the requirements of loss, space, cost, EMI, temperature performance and reliability. In this study, the research direction includes the core material used in the magnetic components, core type and shape. This study discuss the inductor’s parameters such as: effective cross-sectional area (Ae), effective magnetic length (Le) and the copper window area (Wa) of the winding and refer to the specification IEC 60205 to find the appropriate core size, shape and volume for the PFC inductor. Then the copper wire is introduced. The flat wire coil made from the flat wire is used for making the inductor. The advantages and characteristics of the flat wire coil are also analyzed.
Since most of the power inductors require manual winding, the PFC inductor is no exception. This study uses an assembled coil of EE-type iron core instead of toroid core. EE-type core material can be mixed with ferrite and powder core, which core parameters include Ae, Le are designed by myself.
Through the calculation of the efficiency and volume, this study evaluates the copper loss and core loss for choosing the appropriate material. The flat coil is made by automatic winding machine, which can assemble the core and coil automatically. The biggest advantage for this option include automatic production, increasing the power density of the power supply, reducing labor costs, enhancing production efficiency and improving the utilization space of the power supply.

並列關鍵字

Power Factor Correction ； Switching Power Supply ； IEC 60205 ； Flat Wire Coil

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