The design of compact and cost effective products with maximum possible performace, keeps our technical staff constantly involved in Research and Development activities.
Calculation of power losses in inductive components
The calculation of power losses in magnetic components for high frequency is more complex than people generally think and requires the knowledge of a vast bibliography.
This is not sufficient, though; experience shows that there are some cases where additional losses arise which are not addressed by the current bibliography.
Itacoil invested tens of thousands of man-hours in Research and Development activities and in the implementation of effective tools.
The available tools
Many cheap or free tools available on the web provide a quick estimation of losses, but the errors they introduce are misleading for the purpose of optimization.
There are also many commercial tools with different accuracy levels, up to the Finite Elements Analysis (FEA).
Nevertheless, these tools require a great ouflow of resources for every new product, which can only be justified by the production of extremely large quantities.
To allow a deep and accurate optimization of our products at a reasonable cost, we are constantly engaged in the development of proprietary software for power applications of the most popular topologies, based on the results of our Research and Development activities.
The considerable R&D investments have led us to define through the years algorithms for optimal design and automation of a good part of the operations.
We also internally developed a dedicated Spice simulation engine which is way faster than commercial simulators.
It is perfectly integrated into the environment, which knows all the constraints and all the parametric / dimensional characteristics of each component, including the relevant features of ferrite materials and winding wires that we use.
The absence of an early definition of the necessary safety prescriptions for a transformer is a frequent cause of non-compliance during the certification of electronic devices.
This generates costs, delays and the necessity of a revision of the transformer and sometimes of the whole project.
Indeed, the worsening of some parameters or even the shift to a larger transformer size is often caused by a late increase in safety requirements.
We have therefore created a pre-compliance analysis tool for the early definition of Creepage, Clearance, DTI and Dielectric strength according to EN61558-1, EN61558-2-1, EN61558-2-4, EN61558-2-6, EN61558-2-16 (transformers) and EN61347-1, EN61347-2-13 (lighting).
Since the EN61558 standards are referred to in many other standards regarding electronic products, the validity of our pre-compliance tool extends to many other equipment.
The efficiency of this tool, along with our involvement in the regulatory work of the Technical Committee CEI CT96 (EN61558 standards), allows us to provide a support that cannot be easily found elsewhere, and which is highly appreciated by our customers.
With regard to LLC and LCC resonant topologies, increasingly used for their universally recognized benefits, the functions of our tools are not limited to the design of the transformer itself, but extend to the design of the optimal tank, considering:
– all the customer’s requirements
– the constraints and interrelations between the elements that compose the tank
– the ZVS retention at every operating condition and tolerance of the involved components.
This assures the realization of top level converters avoiding the classic reiterations of samplings and tests which, by the way, do not reach the same degree of optimization.
We work alongside the electronic designer
To date our rate of approval of the first sampling defined by design is around 97%, up to 99% for the LLC topology.
Moreover the electronic designer is relieved from onerous activities and time to market is considerably reduced.