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advanced softmagnetic materials for electromagnetic compatibility - EMC
MAGNET-TECHNOLOGIEMAGNETEC
© MAGNETEC GmbH, Langenselbold www.magnetec.de 05/2002 Dr. Fe 1/35
Advanced softmagnetic materials for electromagnetic Advanced softmagnetic materials for electromagnetic compatibilitycompatibility –– EMCEMC
advanced softmagnetic materials for electromagnetic compatibility - EMC
MAGNET-TECHNOLOGIEMAGNETEC
© MAGNETEC GmbH, Langenselbold www.magnetec.de 05/2002 Dr. Fe 2/35
- EMC/EMI basics
- mains filters and current compensated chokes
- comparison: nano and ferrite cores
- production process of nanocrystalline cores
Content of presentation
advanced softmagnetic materials for electromagnetic compatibility - EMC
MAGNET-TECHNOLOGIEMAGNETEC
© MAGNETEC GmbH, Langenselbold www.magnetec.de 05/2002 Dr. Fe 3/35
electromagnetical compatibility (EMC)
can be described as a - required - state:
„ the ability of a device, to work satisfactory in its electromagnetical surrounding, without generating disturbing noise, which could be
unacceptable for other devices.“
(EMV-Richtlinie 89/336/EWG bzw. EMVG)
Currently, the global electromagnetical background noise level doubles every three years ! 1)
EMC basics: definition of EMC
1) Schaffner EMV AG
advanced softmagnetic materials for electromagnetic compatibility - EMC
MAGNET-TECHNOLOGIEMAGNETEC
© MAGNETEC GmbH, Langenselbold www.magnetec.de 05/2002 Dr. Fe 4/35
Steep dU/dt switching edges of mircroprocessors or powertransistors (IGBT) or pulsed currents drawn from the mainssupply line of switched mode power supplies (SMPS) are the main reason for the unwanted emsissions of discrete or continuous RF energy.Examples:- digital telecommunication equipment (ISDN, GSM)- electronical power supplies for lightening applications- any kind of voltage converter using SMPS technology- variable speed drives- white goods with microprocessors and variable speed drives
EMC basics: sources of RF noise emissions
advanced softmagnetic materials for electromagnetic compatibility - EMC
MAGNET-TECHNOLOGIEMAGNETEC
© MAGNETEC GmbH, Langenselbold www.magnetec.de 05/2002 Dr. Fe 5/35
Comparison: 50Hz vs. switched mode power supply
50-Hz-mains adaptor - no RF- noise level but huge & heavy
230V-mains~
rectifierBig 50 Hz-trafo
smootheningDC-output
230V-mains~
small 50 kHz-trafo
switch EMI-filter
rectifier smooth. DC-output
SMPS - EMI filter required, compact, light weight, highly efficient
+-
+-
advanced softmagnetic materials for electromagnetic compatibility - EMC
MAGNET-TECHNOLOGIEMAGNETEC
© MAGNETEC GmbH, Langenselbold www.magnetec.de 05/2002 Dr. Fe 6/35
50-Hz-technologyexample: adaptor
Ps = 6 VA (12V / 0,5A) m = 440g η = 38 %
SMPSexample: notebook Ps = 30VA (15V / 2A)
m = 220g η up to 95 %
SMPS technology: significant reduction of size and weight
advanced softmagnetic materials for electromagnetic compatibility - EMC
MAGNET-TECHNOLOGIEMAGNETEC
© MAGNETEC GmbH, Langenselbold www.magnetec.de 05/2002 Dr. Fe 7/35
RF sourceemissionradiation
radiated noise distribution
conducted noise distribution
RF drainimmunity
Radiationnoise current noise voltage
possible ways of distribution of RF noise
capacitive andinductive coupling
E-fieldH-field
Is
Us
EMC basics: scenario
advanced softmagnetic materials for electromagnetic compatibility - EMC
MAGNET-TECHNOLOGIEMAGNETEC
© MAGNETEC GmbH, Langenselbold www.magnetec.de 05/2002 Dr. Fe 8/35
asyn-chronous motor
variable speed drive (inverter) = source
~~~rectifier dc-link
control circuit
PWM inverter
DC DC~~e.g.
ISA
0
10
20
30
40
50
60
70
100 1000 10000 100000frequency [kHz]
Un
ois
e [
dB
µV
]
0
10
20
30
40
50
60
70
100 1000 10000 100000frequency [kHz]
Un
ois
e [
dB
µV
]
rf
variable voltage & frequency
EMC basics: inverter drive as rf-noise source
advanced softmagnetic materials for electromagnetic compatibility - EMC
MAGNET-TECHNOLOGIEMAGNETEC
© MAGNETEC GmbH, Langenselbold www.magnetec.de 05/2002 Dr. Fe 9/35
EMC basics: sources of RF noise emissions
typical voltage andharmonics in a variable speed drive (inverter) –used in many futurePowerNet systems. Thoseunwanted rf-signals are distributed over all connected wiring systems
fundamental wave 4 kHz
0 20 40 60 80 100 kHz [f]0 20 40 60 80 100 kHz [f]
t = 50µs/unitt = 50µs/unit
T = 250µsT = 250µs
harmonics
advanced softmagnetic materials for electromagnetic compatibility - EMC
MAGNET-TECHNOLOGIEMAGNETEC
© MAGNETEC GmbH, Langenselbold www.magnetec.de 05/2002 Dr. Fe 10/35
~am
ount
%
100
50
01 kHz 100 1 MHz 1GHz10 10010
frequency f
EMC basics: ways of distribution of RF noise
typical distribution of emitted energy as a function of frequency
radiated emission⇒ shielding
MW SW FMLW
conducted emission⇒ filter
advanced softmagnetic materials for electromagnetic compatibility - EMC
MAGNET-TECHNOLOGIEMAGNETEC
© MAGNETEC GmbH, Langenselbold www.magnetec.de 05/2002 Dr. Fe 11/35
1:100.000
1:10.000
1:1.000
30 MHz
100
80
60
40
frequency
Qua
siPe
ak v
olta
geU
[dB
µV
]
class A industrial
class B domestic
EMC basics: RF noise level limits
noise level-limits of EN 55011 (common mode, conducted, 50Ω-system)
150 kHz
advanced softmagnetic materials for electromagnetic compatibility - EMC
MAGNET-TECHNOLOGIEMAGNETEC
© MAGNETEC GmbH, Langenselbold www.magnetec.de 05/2002 Dr. Fe 12/35
EMC basics: measurement setup for RF noise
reference ground
test device artificalmains
test receiver
woodentable
all values in cm
advanced softmagnetic materials for electromagnetic compatibility - EMC
MAGNET-TECHNOLOGIEMAGNETEC
© MAGNETEC GmbH, Langenselbold www.magnetec.de 05/2002 Dr. Fe 13/35
EMC basics: real noise level spectrum (quasi-peak)
1 10 f [MHz]0,1
Us
[dB
µ V] 80
40
0
60
20
80
40
0
60
20
Us
[dB
µ V]
poor filtering, limits of EN55011, class Bare exceeded
appropriate filtering, limits of EN55011,class B are met
advanced softmagnetic materials for electromagnetic compatibility - EMC
MAGNET-TECHNOLOGIEMAGNETEC
© MAGNETEC GmbH, Langenselbold www.magnetec.de 05/2002 Dr. Fe 14/35
EMC basics: future trends and outlook
-Increasing number of unwanted RF-noise sourcesresulting in a continuous increase of background level- regulations will be getting more stringent- regulations will be defined in new - new regulations to come- new noise sources will come- contious increase of costs for filtering measures- global introduction of emc regulations
advanced softmagnetic materials for electromagnetic compatibility - EMC
MAGNET-TECHNOLOGIEMAGNETEC
© MAGNETEC GmbH, Langenselbold www.magnetec.de 05/2002 Dr. Fe 15/35
EMC basics: mains filter
240Vmains
loadCx1 Cx2
Cy2
Cy2
L
basic circuitry of a EMI mains filter
Cxn X-capacitor
Cyn Y-capacitor
L current compensated choke
R discharge resistor
L1
N R
Filter
PE
advanced softmagnetic materials for electromagnetic compatibility - EMC
MAGNET-TECHNOLOGIEMAGNETEC
© MAGNETEC GmbH, Langenselbold www.magnetec.de 05/2002 Dr. Fe 16/35
EMC basics: working principle of mains filters
EMI filters are commonly desinged as reflecting low-pass-filtersausgelegt, this means, they work according to the principle of rf-mismatch.Thus, a part of the high-frequency currents are ‚deviated‘ – the other part will be aborped – e.g. in form of core losses and other mechanisms.
Cx1 Cx1
Cy2
Cy2
Lstreu
Cx1 Cx2
Cy2
Cy2
LN
differential modenoisef < 500kHz
common modenoise
f > 500kHz
Propagation of noise currents
source of noise
noise drain
noise drain
source of noise
advanced softmagnetic materials for electromagnetic compatibility - EMC
MAGNET-TECHNOLOGIEMAGNETEC
© MAGNETEC GmbH, Langenselbold www.magnetec.de 05/2002 Dr. Fe 17/35
EMC basics: setup of attenuation level measurement
conforming test setup of attenuation level αe
1:1
50 Ω
measuring receiver(selective voltmeter)
test item (filter)
1:1
50 Ω
measuring generator(150kHz-30MHz)
U1 U2
αe= 20 log U1
2 U2
[dB]
advanced softmagnetic materials for electromagnetic compatibility - EMC
MAGNET-TECHNOLOGIEMAGNETEC
© MAGNETEC GmbH, Langenselbold www.magnetec.de 05/2002 Dr. Fe 18/35
working principle of a current compensated choke for attenuation of common mode RF noise
EMC basics: principle of common mode chokes
single phase version
three-phase version
load current
RF current
Hload = 0
HRF ≠ 0
load currentload current
RF currentRF current
Hload = 0Hload = 0
HRF ≠ 0HRF ≠ 0
advanced softmagnetic materials for electromagnetic compatibility - EMC
MAGNET-TECHNOLOGIEMAGNETEC
© MAGNETEC GmbH, Langenselbold www.magnetec.de 05/2002 Dr. Fe 19/35
main requirementsmain requirements on a EMCon a EMC filter chokefilter choke::
high impedance (f = 150 kHz to 30 MHz)
Z(f) = ωL(f) = 2πf L(f)
L(f) = AL n2 mit AL = µ0 µr(f) Afe/lf
EMC basics: choice of softmagnetic material
number of turns iron cross sectionpermeability !
advanced softmagnetic materials for electromagnetic compatibility - EMC
MAGNET-TECHNOLOGIEMAGNETEC
© MAGNETEC GmbH, Langenselbold www.magnetec.de 05/2002 Dr. Fe 20/35
Feldstärke H →
Indu
ktio
n B
→
Bs
Hc
Br
Hs
Characteristics of softnagnetic alloys: Hysteresis loop
Bs: saturation lux density (high!) Br: remanence (low!) Hc: coercitivity field strength (low!) Hs: saturation field strength (high!)
advanced softmagnetic materials for electromagnetic compatibility - EMC
MAGNET-TECHNOLOGIEMAGNETEC
© MAGNETEC GmbH, Langenselbold www.magnetec.de 05/2002 Dr. Fe 21/35
- 1987: patent for a completely new softmagnetic materialwith excellent properties by Yoshizawa, Oguma andYamauchi (Hitachi, Japan)alloy composition: Fe73Cu1Nb3Si16B7production process: rapid solidificationmaterial structure: nanocrystalline; i.e. grain size 15 nm
- 1992: markt launch by VACUUMSCHMELZE(VITROPERM®) and HITACHI Metals (FINEMET®)
- since 1995: introduction into several industrial applications of power electronics and telecommunication
- 1999: 3. Source : MAGNETEC (NANOPERM®)
History of nanocrystalline alloys
advanced softmagnetic materials for electromagnetic compatibility - EMC
MAGNET-TECHNOLOGIEMAGNETEC
© MAGNETEC GmbH, Langenselbold www.magnetec.de 05/2002 Dr. Fe 22/35
Comparison of materials
Alloy Permeabilityµ‘r (10 / 100kHz)
Saturation inductionBs [T] (25 / 100°C)
Curie-temp.Tc [°C]
max. workingtemp. Tmax [°C]
Ferrite 3E7 15.000 / 12.000 0,38 / 0,21 >130 95Ferrite T38 10.000 / 10.000 0,38 / 0,23 >130 95
NANOPERM 100.000 / 20.00080.000 / 28.000 1,2 / 1,18 600 120 (180)30.000 / 20.000
NANOPERM vs. Ferrit:NANOPERM vs. Ferrit:- permeability - up to a factor of 10 (!)
- saturation induction - factor 3 - working temperature range - up to 180°C
- disadvantage: price ~ factor 1,5 - 2 (functional value)
⇒ advanced, smaller and lighter components ⇐
advanced softmagnetic materials for electromagnetic compatibility - EMC
MAGNET-TECHNOLOGIEMAGNETEC
© MAGNETEC GmbH, Langenselbold www.magnetec.de 05/2002 Dr. Fe 23/35
-1,5
-1,0
-0,5
0
0,5
1,0
1,5
-1000 -500 0 500 1000 H [mA/cm]
B [T
]
Ferrite T 38 µ = 10.000
NANOPERM
f = 1 Hz
µ = 80.000 µ = 30.000
hysteresis loops, saturation field as a function of permeability level
Comparison of materials
advanced softmagnetic materials for electromagnetic compatibility - EMC
MAGNET-TECHNOLOGIEMAGNETEC
© MAGNETEC GmbH, Langenselbold www.magnetec.de 05/2002 Dr. Fe 24/35
Comparison of materials
permeability as a function of temperaturepermeability as a function of temperature
0
10.000
20.000
30.000
40.000
50.000
-30 20 70 120 170T [°C]
perm
eabi
liy @
10k
Hz/
3mA
/cm
180
NANOPERM
Ferrite
max. for Ferrite:
about 120°C
max. for Ferrite:
about 120°C
advanced softmagnetic materials for electromagnetic compatibility - EMC
MAGNET-TECHNOLOGIEMAGNETEC
© MAGNETEC GmbH, Langenselbold www.magnetec.de 05/2002 Dr. Fe 25/35
Comparison of materials
saturation flux density as a function of temperature Tsaturation flux density as a function of temperature T
0
0,2
0,4
0,6
0,8
1
1,2
1,4
0 100 200 300 400T [°C]
satu
rati
on in
du
ctio
n B
sat
[T]
NANOPERM
FerriteN67
T38
max. for Ferrite:
about 120°C
max. for Ferrite:
about 120°C
advanced softmagnetic materials for electromagnetic compatibility - EMC
MAGNET-TECHNOLOGIEMAGNETEC
© MAGNETEC GmbH, Langenselbold www.magnetec.de 05/2002 Dr. Fe 26/35
Comparison of materials
typical impedance curve at same core geometry Ø=30mm, 22 turnstypical impedance curve at same core geometry Ø=30mm, 22 turns
0
10
20
30
40
50
60
0,01 0,1 1,0 10,0 100,0frequency f (MHz)
atte
nuat
ion
leve
l [dB
]
NANOPERM
Ferrite improved attenuation
below 500 kHz
improved attenuation
below 500 kHz
advanced softmagnetic materials for electromagnetic compatibility - EMC
MAGNET-TECHNOLOGIEMAGNETEC
© MAGNETEC GmbH, Langenselbold www.magnetec.de 05/2002 Dr. Fe 27/35
Comparison of materials
typical impedance curve for different core geometriestypical impedance curve for different core geometries
20
10 100 f [kHz]
impe
danc
e Z
[k Ω
]
4
12
1.000 10.000 100.000
NANOPERM∅ = 40 mm
Ferrite∅ = 63 mm
volume reduction
> 50%
volume reduction
> 50%
advanced softmagnetic materials for electromagnetic compatibility - EMC
MAGNET-TECHNOLOGIEMAGNETEC
© MAGNETEC GmbH, Langenselbold www.magnetec.de 05/2002 Dr. Fe 28/35
0
20
40
60
80
100
120
0,1 1 10 100frequency f [MHz]
nois
e le
vel [
dbµV
]
Ferrite Ø: 63mm, 3x22 turns, m = 380g
NANOPERM Ø: 40 mm, 3x32 turns, m = 94g
achieving more stringent noise limits even at a smaller build volume
Comparison of materials
advanced softmagnetic materials for electromagnetic compatibility - EMC
MAGNET-TECHNOLOGIEMAGNETEC
© MAGNETEC GmbH, Langenselbold www.magnetec.de 05/2002 Dr. Fe 29/35
Comparison of build volume Nano/Ferrite Chokes
NANOPERM-chokeIN = 3 x 25A @ 60°C
LN = 3 x 1,6 mH @ 10kHzm = 120g
Ferrite-chokeIN = 3 x 25A @ 40°C
LN = 3 x 1,3 mH @ 10kHzm = 350g
73 mm
39 mm25 mm
59 mm
volume reduction 60% weight reduction 65 %
volume reduction 60% weight reduction 65 %
advanced softmagnetic materials for electromagnetic compatibility - EMC
MAGNET-TECHNOLOGIEMAGNETEC
© MAGNETEC GmbH, Langenselbold www.magnetec.de 05/2002 Dr. Fe 30/35
principle of production process of rapidly quenched ribbons
melt, T= 1200°C
ribbon thickness ~20µm
v = 100km/h
Cu-wheel, T = 20°C
amorphousribbon
ceramik-nozzle
© AMT
advanced softmagnetic materials for electromagnetic compatibility - EMC
MAGNET-TECHNOLOGIEMAGNETEC
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cutting of ribbons with high precision knives
advanced softmagnetic materials for electromagnetic compatibility - EMC
MAGNET-TECHNOLOGIEMAGNETEC
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automatic winding process of tape wound cores
advanced softmagnetic materials for electromagnetic compatibility - EMC
MAGNET-TECHNOLOGIEMAGNETEC
© MAGNETEC GmbH, Langenselbold www.magnetec.de 05/2002 Dr. Fe 33/35
furnace and batch of cores for magnetic-field treatment
60 cm
300 cm
advanced softmagnetic materials for electromagnetic compatibility - EMC
MAGNET-TECHNOLOGIEMAGNETEC
© MAGNETEC GmbH, Langenselbold www.magnetec.de 05/2002 Dr. Fe 34/35
protective epoxy coating of tape wound cores
advanced softmagnetic materials for electromagnetic compatibility - EMC
MAGNET-TECHNOLOGIEMAGNETEC
© MAGNETEC GmbH, Langenselbold www.magnetec.de 05/2002 Dr. Fe 35/35
available nano products – core and choke types
160 mm
tape wound cores from
10 ... 200 mm ∅
single phase EMC chokes up to I = 60A
three phase EMC chokes
up to I = 200A
Recommended