USER MANUAL

APPLICATION NAME

MAGNETIC DESIGN TOOL

LAST APPLICATION VERSION 5.5.1.

PROGRAMMED BY JIŘÍ VRÁŽDIL
AUTHOR OF USER MANUAL JIŘÍ VRÁŽDIL
DATE OF ISSUE 6/13/2018
UPDATING DATE 6/13/2018

Contact:
jiri.vrazdil@epcos.com

 TDK. Reproduction, publication and dissemination of this publication, enclosures hereto and the information
contained therein without EPCOS' prior express consent is prohibited
CONTENTS
1. Introduction ........................................................................................................ 4
1.1. Fundamentals .............................................................................................. 4
1.2. Subprograms ............................................................................................... 4
1.2.1. Material Form......................................................................................... 4
1.2.2. Core Form.............................................................................................. 4
1.2.3. Graph Control ........................................................................................ 4
1.2.4. Starting the Program .............................................................................. 5
1.2.5. Exiting the Program ............................................................................... 5
2. Fundamentals on Operation .............................................................................. 5
2.1. Selection of the Material / Core.................................................................... 5
2.2. Data Point Reader ....................................................................................... 5
2.3. Graph Control .............................................................................................. 5
2.4. Graph Output ............................................................................................... 5
2.5. Input Fields .................................................................................................. 5
2.6. Output Fields ............................................................................................... 5
3. Material Form .................................................................................................... 6
3.1. Hysteresis Loop ........................................................................................... 6
3.1.1. Procedure .............................................................................................. 6
3.1.2. Zoom Function ....................................................................................... 7
3.2. Initial Permeability........................................................................................ 7
3.2.1. Procedure .............................................................................................. 7
3.2.2. Intermediate Values of μi ....................................................................... 8
3.3. Power Loss .................................................................................................. 9
3.3.1. Procedure .............................................................................................. 9
3.3.2. Measured values of PL ........................................................................ 10
3.3.3. Amplitude Permeability ........................................................................ 11
3.3.4. Procedure ............................................................................................ 11
3.3.5. Intermediate values of μa .................................................................... 12
3.4. Complex Permeability ................................................................................ 13
3.4.1. Procedure ............................................................................................ 13
3.4.2. Intermediate values of μs’ (f), μs’’ (f), μp’ (f), μp’’ (f), gp(f), tanδ/μi (f) or
Z_N(f) 14
4. Core Form ....................................................................................................... 15

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 4.1. Effective Permeability ................................................................................ 15
4.1.1. Procedure ............................................................................................ 15
4.2. Transferable Power Ptrans ........................................................................... 16
4.2.1. Procedure ............................................................................................ 16
4.2.2. Further Description of the Input Fields ................................................. 17
4.3. Data Overview ........................................................................................... 18
4.3.1. Procedure ............................................................................................ 18
4.4. AL-values ................................................................................................... 19
4.4.1. Procedure ............................................................................................ 19
4.5. DC-Bias ..................................................................................................... 21
4.5.1. Procedure ............................................................................................ 21
4.5.2. Underlying Formulae 1) : ..................................................................... 22
4.6. Third Harmonic Distortion .......................................................................... 22
4.6.1. Procedure ............................................................................................ 22
4.6.2. Underlying Formulae: .......................................................................... 23
4.7. Wire Design ............................................................................................... 24
4.7.1. Procedure ............................................................................................ 24
4.7.2. Underlying Formulae: .......................................................................... 25
5. Graph Control .................................................................................................. 27
5.1. Introduction ................................................................................................ 27
5.2. Graph Layout ............................................................................................. 27
5.3. Printing a graph ......................................................................................... 28
5.4. Exporting a graph ...................................................................................... 28
5.4.1. Exporting of graph as file ..................................................................... 29
5.4.2. Copying a graph via the clipboard ....................................................... 29
5.4.3. Exporting data into external file............................................................ 29
6. Settings............................................................................................................ 30
7. Reference List ................................................................................................. 31

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1. Introduction

1.1. Fundamentals
The Magnetic Design Tool provides the convenient access to the material data of the
available EPCOS ferrite materials and their integration in the process of design in digital
form. The parameters on which the design tool is based, such as hysteresis loop, power loss,
initial permeability, amplitude permeability and complex permeability are formed by the
measurement data of the available EPCOS ferrite materials. These measurement data can
be represented as a graph and compared to one another.
The graphs created can be printed, or pasted into other Windows applications via the
clipboard. A simple editor lets you take notes relating to the selection process as you are
working with the Magnetic Design Tool.

1.2. Subprograms

1.2.1. Material Form

In dependence of the material selected, this subprogram serves to graphically represent
• a hysteresis loop
• the initial permeability vs. temperature
• the power loss vs. frequency, flux density, temperature and the performance factor
• the amplitude permeability vs. flux density or field strength
• the complex permeability vs. frequency in serial and parallel representation

1.2.2. Core Form

In dependence of the material and core form selected, this subprogram serves to:
• obtain a data overview,
• calculate the AL-value in dependence of the air gap (or vice versa)
• represent the effective permeability over temperature,
• determine the transferable power Ptrans
• calculate third harmonic distortion under circuit conditions
• calculate the appropriate air gap, Al value and the number of turns for a given
permeability drop p [%] , representing the curve of inductance or permeability vs. DC-
bias
• display the ratio of the AC- to DC-resistance vs. frequency.

1.2.3. Graph Control

In the Graph Control window, the representation of the graphs can be defined, the
represented graphs can be printed, and they can be pasted into other Windows applications
via the Clipboard.
This window can be opened from any subprogram supporting graphic representation.

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 1.2.4. Starting the Program
• Start the program by double-clicking on the Ferrite Magnetics icon in the Data Book
Library program group.
• Click on the OK button on the introduction screen.
The program will be started with a blank editor window opened.

1.2.5. Exiting the Program

• Select the Exit menu item in the File pull-down menu. The program will be terminated.

2. Fundamentals on Operation
The basic operational procedures and the button assignments for the subprograms Material
Properties and Core Calculations are identical. For this reason, they are described globally in
this context.

2.1. Selection of the Material /

Core
Drop-down menus for selecting the desired material and core form. Only those materials and
core forms can be selected for which the desired representation (calculation) is performable.

2.2. Data Point Reader

Position the mouse pointer on a point of a measured curve on the screen and click on it with
the left mouse button. The corresponding measured value will be displayed in the Data Point
Reader window.

2.3. Graph Control

Clicking on these buttons calls the Graph Control window, in which the representation type of
the graphs can be defined, the graphs displayed can be printed, and in which they can be
made available for other Windows applications via the Clipboard. See “Graph Control” on
page 26.

2.4. Graph Output

The graphs are output in this window area. By selecting multiple materials and/or core forms,
graphs can be superimposed and thus conveniently compared.

2.5. Input Fields

Data for calculations can be entered in fields underlayed in white. The input is confirmed by
pressing the Return key.

2.6. Output Fields

Output fields are underlayed in grey. They merely serve for displaying the results of
calculations or measured values and cannot be modified.

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3. Material Form

3.1. Hysteresis Loop

The program can represent the hysteresis loops at the temperatures of T = 25 °C and T =
100 °C for all available EPCOS ferrite materials that are included in the data book. For every
point of the graph, a pair of values H, B can be displayed.

3.1.1. Procedure
• Click on the Material Form button in the main window. The Material data window will
be opened.
• Select Hysteresis.
• Select the desired material.
• Select the desired temperature.
The hysteresis loop will be displayed.

Fig. 3.1 – Hysteresis loop

Move mouse cursor on a point of the graph to view the associated pair of values B and H in
the Data Point Reader. If you want to zoom in the graph, click on the graph by left mouse
button and select area to zoom in. If you want to zoom out the graph to default scale, click on

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the graph by left mouse button and move the mouse to the left upper corner of the graph. If
you click on the graph by right mouse button, you can move in current scale of the graph.

3.1.2. Zoom Function

To be able to view the hysteresis loop of the ferrites more closely, the program provides a
zoom function (only valid for power materials in this version).
Zoom in - Click into the area of the graph with the left mouse button.
Zoom out - Click into the area of the graph with the right mouse button.

3.2. Initial Permeability

For all available EPCOS ferrite materials, the initial permeability as a function of the
temperature T can be displayed. For every point of the graph, a pair of values T, μi can be
displayed. It is possible to display multiple curves in one graph. This provides an optimal
material comparison.

3.2.1. Procedure
• Click on the Material Form button in the main window. The Material data window will
be opened.
• Select μi vs. T.
• Select the desired material.
The initial permeability as a function of the temperature will be displayed.

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Fig. 3.2 - Initial permeability
• Click on measuring points in the curve to view the value μi for a specific temperature
in the DataPoint Reader.

3.2.2. Intermediate Values of μi

It is also possible to calculate intermediate values of μi relating to the measuring points
(linear interpolation).
• Enter the temperature T [°C] in the input field and click the yellow “calculate” button.
The value calculated for the selected material will be displayed in the μi output field.

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 3.3. Power Loss
For all available EPCOS power materials, the power loss per volume and per mass can be
represented as a function of the temperature T, the frequency f and the flux density B. The
number of measurement data available in the program exceeds the number of data specified
in the data book by far. It is possible to display multiple curves in one graph. This provides an
optimum material comparison.

3.3.1. Procedure
• Click on the Material Form button in the main window. The Material data window will
be opened.
• Select Pv vs. f, B, T.
• Select the desired material.
• Define the parameters that are to be presented on the X- and Y-axes.
• Select the frequency f, the flux density B or the temperature T (depending on the
setting of the X-axis).
Depending on the setting, the power loss will be displayed as a function of T, f or B.

Fig. 3.3 - Power loss vs. T

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Fig. 3.4 - Power loss vs. f
• Click on measuring points to view the associated pair of values in the Data Point
Reader.

3.3.2. Measured values of PL

The measured power losses for appropriate combinations of temperature, frequency and flux
density can also be displayed.
• Enter the temperature T [°C], the frequency f [kHz] and the flux density B [mT] in the
input fields.
The measured values for the selected material will be displayed in the PL output field.

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 3.3.3. Amplitude Permeability
For all available EPCOS power materials, the amplitude permeability as a function of the flux
density B or the field strength H can be represented at the temperatures of T = 25 °C and T =
100 °C. For every point of the graph, a pair of values B, μa or H, μa can be displayed. It is
possible to display multiple curves in one graph. This provides an optimum material
comparison.

3.3.4. Procedure
• Click on the Material Form button in the main window. The Material data window will
be opened.
• Select μa vs. B.
• Select the desired material.
• Select the desired temperature.
• Select the measurand (B, H) that is to be represented on the X-axis.
The amplitude permeability as a function of the flux density B or of the field strength H will be
displayed.

Fig. 3.5 - Amplitude permeability

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 • Click on a measuring point in the curve to view the associated pair of values B, μa or
H, μa in the Data Point Reader.

3.3.5. Intermediate values of μa

It is also possible to calculate intermediate values of μa relating to the measuring points. The
measurand you can enter depends on the setting for the X-axis.
• Enter the desired value in the input field (H or B) and click the yellow “calculate”
button.
The value calculated for the selected material will be displayed in the μa output field.

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 3.4. Complex Permeability
For all available EPCOS materials, the complex permeability can be represented as a
function of the frequency. You can select one of seven display types μs’ (f), μs’’ (f), μp’ (f),
μp’’ (f), gp(f), tanδ/μi(f) or Z_N(f). It is possible to display multiple curves in one graph. The
different parameters provide an optimum material comparison for various applications:
• the relative loss factor tan/μ for filter inductors with high Q
• the parallel conductance gp(f), which is directly proportional to the insertion loss, for
broadband transformers
• the normalized impedance Z_N(f) for EMI suppressors
The relationship among the different parameters is given as follows:

3.4.1. Procedure
• Click on the Material Form button in the main window. The Material data window will
be opened.
• Select μ’-μ’’ vs. f .
• Select the desired material.
• Select whether μs’ (f), μs’’ (f), μp’ (f), μp’’ (f), gp(f), tan/μi (f) or Z_N(f) are to be
represented.

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The graph will be displayed.

Fig. 3.6 - Complex permeability

• Click on measuring points in the curve to view the associated pairs of values in the
Data Point Reader.

3.4.2. Intermediate values of μs’ (f), μs’’ (f), μp’ (f), μp’’ (f), gp(f),
δ/μi (f) or Z_N(f)
tanδ
• Enter the desired frequency in the input field and click the yellow “calculate” button. μ’
(f), μ’’ (f) and tan/μi will be displayed.

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4. Core Form

4.1. Effective Permeability

For all available EPCOS materials, the core-form-specific μe(T) characteristics based on the
μi(T) material curve (measured on ring cores) can be calculated. This calculation is
performed according to the well-known equation:

It is possible to display multiple curves in one graph. This provides an optimum comparison
(e.g. change of the air gap).

4.1.1. Procedure
• Click on the Core Form button in the main window. The Core data window will be
opened.
• Select μe vs. T.
• Select the desired core.
• Specify the core form (optionally: low profile, with hole). Note: Please observe that not
all combinations are valid (e.g. in low profile, only RM cores are available). Values will
not be output if an invalid combination was specified.
• Select the desired material.
• Select the type of representation μe(T) or (μe(T) - μe(T1))/(μe(T).
• Enter the desired air gap in the s field.
The effective permeability as a function of the temperature will be displayed.

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Fig. 4.1 - Comparison of the effective permeability using different air gaps.
• Click on points in the curve to view the associated pairs of values T, μe in the Data
Point Reader.

4.2. Transferable Power Ptrans

For all power materials and most cores, the transferable power Ptrans can be determined.

4.2.1. Procedure
• Click on the Core Form button in the main window. The Core data window will be
opened.
• Select Ptrans.
• Select the desired core.
• Specify the core form (optionally: low profile, with hole). Note: Please observe that not
all combinations are valid (e.g. in low profile, only RM cores are available). Values will
not be output if an invalid combination was specified.
• Select the desired material.
• Correct for the default thermal resistance Rth value (fre-air convection), if a better
figure is known for your application.

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 • Enter the desired values in the dTCu, dTFe and f input fields.
• Correct for the default copper space factor fCu=0.4 if a better figure is known for your
application.
• If a wire calculation on the selected core type has been performed previously, click
the “get Rac/Rdc” button to consider proximity and skin effects in the Ptrans
calculation.
• Select the appropriate converter type in the pull down menu.
• Ptrans will be displayed in the output field after pressing the yellow “calculate” button.

Fig. 4.2 - Transferable power Trans

4.2.2. Further Description of the Input Fields

fCu: copper space factor
dTCu: copper temperature rise [K]
dTFe: ferrite temperature rise [K]
The transferable power Ptrans of transformers can be calculated by the following
approximation:

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The constant C relates to the operation mode which is:
C=1 in push-pull converters
C=0,71 in single-ended converters
C=0,62 in flyback converters 1) .
Further quantities in equation (1) are the switching frequency f, the sweep of flux density ∆B,
the current density S, the winding cross section AN and the effective area Ae.

4.3. Data Overview

For all EPCOS materials and core shapes, various digital data are represented in the form of
a table.

4.3.1. Procedure
• Click on the Core Form button in the main window.
The Core data window will be opened. Select Data overview.

Fig. 4.3 - Data overview

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 • Select the desired core.
• Specify the core form (optionally: low profile, with hole). Note: Please note that not all
combinations are valid (e.g. in low profile, only RM cores are available). Values will
not be output if an invalid combination was specified.
• Select the desired material.

4.4. AL-values
For all available EPCOS materials, the following calculations can be performed using the
calculator:
• Al as a function of the air gap and vice-versa without taking into account the fringe
flux
• Al as a function of the air gap and vice-versa using the K-factors (only for EE-, EC-,
ER, ETD-, EFD-, EPF-, and ELP-cores in N27, N67, N87)
• The inductance as a function of the Al value and vice-versa

4.4.1. Procedure
• Click on the Core Form button in the main window. The Core data window will be
opened.
• Select AL-value

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Fig. 4.4 - AL-value
• Select the desired core.
• Specify the core form (optionally: low profile, with hole). Note: Please observe that not
all combinations are valid (e.g. in low profile, only RM cores are available). Values will
not be output if an invalid combination was specified.
• Select the desired material.
• Enter the values for the calculation in the input fields and click the yellow “calculate”
button.
The results will be displayed in the associated output fields.

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 4.5. DC-Bias
For all available EPCOS power materials and most core shapes, the reversible permeability
can be calculated as a function of the DC-current as well as of the DC-field with a given Al
value. For this purpose, the temperatures T = 25 °C and T = 100 °C are taken into
consideration. With a given number of turns, the reversible inductance and the magnetic
energy can additionally be calculated.

4.5.1. Procedure
• Click on the DC-Bias button in the main window. The DC-Bias window will be opened.

Fig. 4.5 - DC-Bias

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 • Select the desired core.
• Specify the core form (optionally: low profile, with hole). Note: Please observe that not
all combinations are valid (e.g. in low profile, only RM cores are available). Values will
not be output if an invalid combination was specified.
• Select the desired material.
• Select the desired temperature (T = 25 °C or T = 100 °C).
• Select the measurands that are to be represented on the X- and Y-axes.
• Enter the desired values for the unbiased inductance L in [mH], the DC-current Idc in
[A] and the roll-off p in[%] in the corresponding input fields.
• Click the yellow “calculate” button. The calculated values will be displayed in the
output fields and a corresponding plot shown.
• If you want to change the Al value and/or number of turns N for new plot data, enter
the new values and press the Return key.
The new resulting unbiased inductance and the graph will be displayed.

4.5.2. Underlying Formulae 1) :

• Click on measurement points in the curve to view the associated measured values in
the DataPoint Reader.

4.6. Third Harmonic Distortion

For a given core and a given material, the calculated ratio of the AC-to DC-resistance vs.
Frequency for sinusoidal current waveforms can be displayed.

4.6.1. Procedure
• Click on the Harmonic Distortion button in the main window.

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Fig. 4.6 - Third harmonic distortion
• Select the desired core.
• Specify the core form (optionally: low profile, with hole). Note: Please observe that not
all combinations are valid (e.g. in low profile, only RM cores are available). Values will
not be output if an invalid combination was specified.
• Select the desired material.
• Select the desired input option: turns ratio/inductance/resistances or AL-value/number
of turns/wire diameter
• Enter the desired values in the corresponding input fields. The calculated values will
be displayed in the output fields.

4.6.2. Underlying Formulae:

By using the following equations the third harmonic distortion k3 for the voltage based on
Rayleigh´s hysteresis model can be calculated. The in-circuit distortion k3c follows form
consideration of the impedance conditions.1) ...

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 4.7. Wire Design
For a given core and a given material, the calculated ratio of the AC-to DC-resistance vs.
Frequency for sinusoidal current waveforms can be displayed.

4.7.1. Procedure
• Click on the Wire Calculation button in the main window.

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Fig. 4.7 - Wire design
• Select the desired core.
• Specify the core form (optionally: low profile, with hole). Note: Please observe that not
all combinations are valid (e.g. in low profile, only RM cores are available). Values will
not be output if an invalid combination was specified.
• Select the total number of turns
• Select the number of layers
• Click the yellow “calculate” button
• The graph will be displayed. If the window fill factor fw surpasses 100% a warning
message will be shown.

4.7.2. Underlying Formulae:

By using the following equations the winding copper losses for sinusoidal current can be
estimated. 1) . x stands for the ratio of the wire diameter to the frequency-dependent
penetration depth, m stands for number of layers.

MAGNETIC DESIGN TOOL PAGE 25 (OF 31)

MAGNETIC DESIGN TOOL PAGE 26 (OF 31)
5. Graph Control

5.1. Introduction
In the „Edit Chart“ form you can print graphs, insert graphs in other Windows applications via
the Clipboard and define the representation of the graph.

Fig. 5.1 – Edit chart form

5.2. Graph Layout

In the windows for controlling the graph layout, you can define the appearance of your graph.
Among other things, you can set the background color, select the axis representation and the
desired value range.
Clicking on „Close“ will close the window.

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 5.3. Printing a graph

Fig. 5.2 – Printing of graph

• Select printing orientation
• Select printer
• Click on the Print button.
The graph will be printed on the selected printer.

5.4. Exporting a graph

You can export the current graph as a graphics file or copy it to the Clipboard to make it
available for other Windows applications.

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 5.4.1. Exporting of graph as file

Fig. 5.3 – Graph exporting

• Select the desired data format in the Export window area (Metafile or Bitmap).
• Specify the target by button „Save…“
• Click on the „Save“ button.
The graphics file will be saved.

5.4.2. Copying a graph via the clipboard

Proceed as follows to copy the current graph to the Clipboard to make it available for other
Windows applications:
• Select the desired data format in the Export window area (Metafile or Bitmap).
• Click on the Copy button. The graphics file will be saved.
• Now change to your Windows application (e.g. Word). Position the cursor to the
desired insertion point and select Paste.
The graph will be inserted in your document.

5.4.3. Exporting data into external file

If you want to export data from chart into external file, use following setup (Fig. 17):

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Fig. 17 – Data export
Select desired output format in “Format” group and click on button ‘Save”. Data will be
exported into selected file format (it’s MS Excel on Fig.17).

6. Settings
If you want to change a font of visual controls, select “Settings – Options”. Following form will
be displayed – Fig.18.

Fig. 18 – Options
Click on button “Change” and select desired font. The font will be saved on hard disk and this
font will be used during next running of application.

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7. Reference List
[1] E. C. Snelling [1988], Soft Ferrites, Butterworths, 2nd Edn.
[2] P. L. Dowell [1966], Effects of eddy currents in transformer windings, Proc. IEE, Vol.
113, No. 8.
[3] B. Carstens [1995], Calculating Skin and proximity effect conductor losses in switch
mode magnetics, PCIM’95 seminar notes.
[4] T. Werner, J. Hess [1996], Core loss measurements in high frequency power
materials-measurement methods for the frequency range up to 10 MHz, Proceedings of the
PCIM’96, pg. 611-622.
[5] R. Gaus [1911], Die Gleichung der Kurve der reversiblen Suszeptibilität, Phys. Z. 12,
pp 1053 - 1054
[6] W. Kampczyk, E. Röß [1978], Ferritkerne, Siemens AG
[7] G. Roespel [1978], Effect of the magnetic material on the shape and dimensions of
transformers and chokes in switched-mode power supplies, Siemens AG München, J. of
Magn. and Magn. Materials 9, pp 145 - 149
[8] M. Esguerra [1997] , “Ferrite Core Design for Broadband Design of Telecom
Transformers”, MMPA User´s Conference, Chicago.
8] H. Meuche, M. Esguerra [1999] , “Ferrite Cores for xDSL: Optimum
Selection”EMCW´99, Cincinatti.

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