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Magnetic Builder (Magnetic Design Software, Inductor and Transformer design tool)

PowerEsim is a free web-based software providing power supply (SMPS) design, transformer design, magnetic design, loss analysis, thermal analysis, waveform analysis, MTBF analysis, BOM building, DVT analysis and optimization of power supply (SMPS).
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What is magnetic builder (Inductor and Transformer design tool)? TopClick here to try Online Magnetics Builder (design tool) now

Magnetic Builder is a useful magnetic design software. It is a tool for user to create his/her own magnetic component (inductor and transformer) by selecting different ferrite core, bobbin type and winding method. Engineering drawing will be automatically produced to reduce user work load.

All the transformer and inductor built can be saved and reused onto a power supply, as long as the winding number are matched.

Inductor/Transfomer are necessary parts of switching power supply circuits.
The Advantages of Using Transformers
Transformers used with the three basic topologies offer certain advantages over the simple circuits introduced in the previous section. Namely:

  • They provide isolation between input supply and output DC lines, and between one DC output line and another.

  • Suitable choice of turns ratio can ensure that near optimum duty cycle is used, even when input and output voltages are widely different.

  • The buck, boost and flyback topologies provide outputs which are, respectively, lower, higher, or polarity reversed versions of the input supply. A transformer/inductor can effectively remove all these inherent constraints, and, by so doing, enable any special topological property to be taken advantage of, if desired.

  • A single regulator system can produce more than one separate DC output line by using a number of secondary windings.

  • Reference Software:
    Simple calculator to calculate coils of Transformer and Inductor
    Download PFC Design Tool from Metglas
    Output Inductor Design Tool from Metglas
    Online Inductor Design Calculator Test
    Online Current Transformer Design Software
    Reference Tutorial
    Inductor and Flyback Transformer Design [PDF]
    Inductor Design Procedure[PPT]
    Filter Inductor Design Procedure[PPT]

    Index:
  • What is magnetic builder (Inductor and Transformer design tool)?
  • Create a new transformer
  • Add number of primary and secondary winding
  • Add Bifilar
  • Flux Band
  • Add Primary / Secondary Winding
  • Faraday Shield
  • Add a transformer/inductor to the design
  • Make split winding or parallel winding
  • Customize the winding order
  • Adjust number of turns for each winding
  • Select the wire used for each winding
  • Every change can affect the total loss
  • Every change can affect transformer/inductor loss
  • Some change can affect the Peak Flux
  • Putting transformers in parallel / series
  • Changing the transformer/inductor inductance
  • Select different core shape and manufacturer
  • Select different core material
  • Overall bobbin thickness can be adjusted
  • Adjust the overall creepage tape width
  • Adjust the Overall winding indent
  • Adjust the Overall Multi-Layer Winding setting
  • Change the No. of wire in parallel
  • Adjust the overall wire used in all winding
  • How to change the Winding Wizard option?
  • Change bobbin thickness on each side
  • Configure the bobbin winding window dimension
  • How to change the winding layer usage?
  • Bobbin with split walls
  • Configure number of split walls
  • Configure the thickness of split walls
  • Configure the thickness of each partition
  • Configure tape characteristic in each winding
  • Configure the tape thickness of each winding
  • Configure the number of layer in each winding
  • Configure the tape type used in each winding
  • Configure the dot sign of each winding
  • Define the winding start position of each winding
  • Configure the winding indent of each winding
  • Configure the characteristic of multi-layer winding of each winding
  • Creepage position
  • Creepage width of each winding
  • Change the number of turns of each split winding
  • Locate the winding in which bobbin partition
  • Generate Transformer/Inductor Drawing
  • Designed parameters of a transformer/inductor
  • Change the testing details of Transformer/Inductor Drawing
  • Different type of bobbin can be selected
  • Change the number of pins of bobbin
  • Add/ delete fly pins
  • Configure details of fly pins
  • Define the termination pins of a winding
  • Preview the Transformer/Inductor drawing page
  • Create a new transformer/inductor TopClick here to try Online Magnetics Builder (design tool) now

    Create transformer
    Click “Magnetic Builder” a “Number of Windings” page appear for user to first defining the number of primary winding and number of secondary winding.

    Add number of primary and secondary winding TopClick here to try Online Magnetics Builder (design tool) now

    select number of primary windings
    The number of primary winding and number of secondary winding can be change. The default value is one.


    Add Bifilar TopClick here to try Online Magnetics Builder (design tool) now

    adding bifilar

    1. Move cursor to the winding
    2. The winding will turn RED
    3. Click on the winding and you can see the picture as below
    4. Winding with the same number of turn will be shown and can be selected for bilfilar.

    W2 bifilar with other winding

    Flux Band TopClick here to try Online Magnetics Builder (design tool) now

    Click "flux band"
    Click the button “Flux Band”

    flux band setting
    Two type of flux band are supported. Click the checkbox to add the flux band.


    flux band setting
    After clicked the checkbox, the core with the flux band can be preview. The Flux band thickness and width can be set.

    Add Primary / Secondary Winding TopClick here to try Online Magnetics Builder (design tool) now

    add winding (primary or secondary)

    add extra winding
    Extra Winding can be added by clicking “Add Pri Wdg” or “Add Sec Wdg.” The usage of this feature is recommended for non-operating winding only. User is recommended to preset the proper winding number at the “Number of Windings” page.


    Faraday Shield TopClick here to try Online Magnetics Builder (design tool) now

    faraday shield
    The user can change a particular winding to Faraday Shield. Only extra windings can be changed to Faraday Shield.

    Add a transformer/inductor to the design TopClick here to try Online Magnetics Builder (design tool) now

    add transformer to design
    After creating a new transformer/inductor, you can add it to the design by pressing “Add Component”.
    When the transformer/inductor is added, the message with transformer's designator is shown.
    transformer is added


    Make split winding  or parallel winding  TopClick here to try Online Magnetics Builder (design tool) now

    split winding or parallel winding

    select number of winding
    User can “Split” a winding to several section by choosing from “No. of windings” or Parallel Winding in any winding for sandwiching winding method.

    Customize the winding order  TopClick here to try Online Magnetics Builder (design tool) now

    customize winding order
    The winding order can be changed by the list box. W1 means the most inner layer.

    Adjust number of turns  for each winding TopClick here to try Online Magnetics Builder (design tool) now

    set number of turns
    The number of turns for each winding is shown in the blue button. You can press this button to modify the number of turns.


    Select the wire used for each winding TopClick here to try Online Magnetics Builder (design tool) now

    select wire for winding
    The wire information for each winding is shown in the blue button. It shows the Wire name and the number of parallel wires. You can press this button to modify it.

    Every change can affect the total loss TopClick here to try Online Magnetics Builder (design tool) now

    total loss updated
    The “Total Loss” means the overall losses of the power supply and is shown at the top of the interface and will be automatically updated for any changed in transformer design.

    Every change can affect transformer/inductor loss TopClick here to try Online Magnetics Builder (design tool) now

    transformer loss updated
    The “Transformer Loss” means the losses of the whole transformer and is shown at the top of the interface and will be automatically updated for any changed in transformer design.

    Some change can affect the Peak Flux TopClick here to try Online Magnetics Builder (design tool) now

    peak flux updated
    The “Bm” means the peak flux density of the transformer and is shown at the top of the interface and will be automatically updated for any changed in transformer design.

    Putting transformers in parallel  / series TopClick here to try Online Magnetics Builder (design tool) now

    set parallel or series for transformer
    You can clone the current transformer and produce a set of transformer and place them in parallel or in series.


    Changing the transformer/inductor inductance TopClick here to try Online Magnetics Builder (design tool) now

    set transformer inductance
    Inductance value is shown in the interface. On the left there is a blue button which can be used to modify the inductance.

    Select different core shape  and manufacturer  TopClick here to try Online Magnetics Builder (design tool) now

    click to select core shape and manufacturer
    Information on the selected core and selected magnetic materials is shown. You can press the blue button to change it.

    Select different core material  TopClick here to try Online Magnetics Builder (design tool) now

    change core material in core page
    After you press on “Core Shape”, you can see the following page.
    You can click on “Core Material” button on the bottom right to select different core material.


    Overall bobbin thickness can be adjusted TopClick here to try Online Magnetics Builder (design tool) now

    adjust bobbin thickness
    Overall bobbin thickness is a short cut to change all the left, upper and lower bobbin thickness at once.

    Adjust the overall creepage  tape width TopClick here to try Online Magnetics Builder (design tool) now

    adjust creepage tape width
    Overall creepage tape width is a short cut to change all the upper and lower creepage tape widths in all winding.

    Adjust the Overall winding indent TopClick here to try Online Magnetics Builder (design tool) now

    adjust winding indent
    Overall Winding Indent is a short cut to change all the winding indents in all winding.


    Adjust the Overall Multi-Layer Winding setting TopClick here to try Online Magnetics Builder (design tool) now

    adjust multi-layer winding setting
    Overall Multi-Layer Winding is a short cut to change all the Multi-Layer Winding property.

    Change the No. of wire in parallel TopClick here to try Online Magnetics Builder (design tool) now

    click to change no. of wire in parallel
    After you select the wire (section 7.8.12), you can see the above page.

    Adjust the overall wire used in all winding TopClick here to try Online Magnetics Builder (design tool) now

    click to change all wire
    There is a shortcut button “Change All wire” that can change the wire for all winding by one step only.


    How to change the Winding Wizard option? TopClick here to try Online Magnetics Builder (design tool) now

    Change winding wizard option
    After you press the button “Winding Wizard”, you can see the following page and set the winding wizard option.

    winding wizard option page
    The check box in the “Winding Wizard” page provide a list of  allowable background actions when the wire winding area is bigger than the allowable winding window area.


    Change bobbin thickness on each side TopClick here to try Online Magnetics Builder (design tool) now

    change bobbin setting
    After press the button “Bobbin Setting”, then you can see

    bobbin thickness page
    All four side of the bobbin can be individually adjusted.

    Configure the bobbin winding window dimension TopClick here to try Online Magnetics Builder (design tool) now

    set bobbin winding window dimension
    After press the button “Bobbin Setting”, then you can see

    bobbin winding window dimension


    How to change the winding layer usage? TopClick here to try Online Magnetics Builder (design tool) now

    change winding layer usage
    After press the button “Bobbin Setting”, then you can see

    set winding layer usage
    The winding layer usage is the usage ratio between the allowable bobbin height and Inner Bobbin height.

    Bobbin with split walls TopClick here to try Online Magnetics Builder (design tool) now

    click to open bobbin setting page
    After press the button “Bobbin Setting”, then you can see

    select vertical or parallel split wall
    User can choose Vertical or Horizontal type of split wall.


    Configure number of split walls TopClick here to try Online Magnetics Builder (design tool) now

    click to open bobbin setting page
    After press the button “Bobbin Setting”, then you can see

    select number of split wall
    User can design number of split walls by choosing from “Select No. of Split Walls”

    Configure the thickness of split walls TopClick here to try Online Magnetics Builder (design tool) now

    click to open bobbin setting page
    After press the button “Bobbin Setting”, then you can see

    select thickness of split wall
    User can design the thickness of the split wall by choosing from “Thickness of Split Walls”

     

    Configure the thickness of each partition TopClick here to try Online Magnetics Builder (design tool) now

    If you set more than 1 split walls in section "Configure number of split walls", you can see
    select thickness of each partition
    User can design the individual window height of each partition by clicking the arrows to increase or decrease partition thickness.

    Configure tape characteristic in each winding TopClick here to try Online Magnetics Builder (design tool) now

    click to configure winding construction
    After pressing the button “Winding Construction”, user will see the “Advance Winding Construction” page

    advance winding construction page
    Basically each copper winding has its inherent tape winding for insulation. If no insulation is need set No. of layer to 0.


    Configure the tape thickness of each winding TopClick here to try Online Magnetics Builder (design tool) now

    set thickness of winding
    The thickness of tape can be set by changing the value of “Thickness (mm)”


    Configure the number of layer in each winding TopClick here to try Online Magnetics Builder (design tool) now

    set number of layer
    The no of turn of the tape can be set by changing the value of “No. of Layer”


    Configure the tape type used in each winding TopClick here to try Online Magnetics Builder (design tool) now

    set tape type in each winding
    The material of the tape can also be set by “Type”


     

    Configure the dot sign of each winding TopClick here to try Online Magnetics Builder (design tool) now

    set if winding start at dot sign
    User can choose whether the dot sign is lie with winding started at the “Winding Start at Dot Sign” box.


    Define the winding start position of each winding TopClick here to try Online Magnetics Builder (design tool) now

     

    define winding start at lower part of winding
    User can choose the winding start position at the “Winding Start Position” box.


    Configure the winding indent of each winding TopClick here to try Online Magnetics Builder (design tool) now

    set distributed winding indent
    User can choose how the wire is packed at the “Winding Indent” box.
    Distributed – wire will evenly wind in the allowable winding height.
    Center – wire will be packed tight at center of the allowable winding height.
    Low – wire will be packed tight at lower part of the allowable winding height.
    Upper – wire will packed tight at the upper part of the allowable winding height.


    Configure the characteristic of multi-layer winding of each winding TopClick here to try Online Magnetics Builder (design tool) now

    share wire in mutli-layer
    User can choose how the wire is arranged if more than 1 layer is needed to complete the winding in the “Multi-Layer Winding” box
    Shared – wire will evenly shared in each layer
    Tight – wire will be just tightly wind.


     

    Creepage position TopClick here to try Online Magnetics Builder (design tool) now

    End-To-End creepage position
    User can choose how the creepage tape is placed in the “Creepage Position” box
    End-To-End  – Creepage tape will placed at both end of the allowable winding height
    Tight – Creepage tape will placed just beside the wire.


     

    Creepage width of each winding TopClick here to try Online Magnetics Builder (design tool) now

    Set creepage width
    User can choose how the width of the creepage tapes by changing “Upper Creepage Width” or “Lower Creepage Width” box.


    Change the number of turns of each split winding TopClick here to try Online Magnetics Builder (design tool) now

    set no. of turn
    If more than 1 split sub-winding are made (section 7.8.9), you can change the number of turns of the each split winding by changing “No. of Turn” box.


    Locate the winding in which bobbin partition  TopClick here to try Online Magnetics Builder (design tool) now

    set no. of winding partition
    If more than one partition (section 7.8.31 & 7.8.32), user can locate the winding in any partition by changing “Winding’s Partition” box.


    Generate Transformer/Inductor Drawing TopClick here to try Online Magnetics Builder (design tool) now

    click to generate transformer drawing

    fill in details for transformer
    After pressing “Generate Drawing”, user can fill in all the detail information for making a professional transformer drawing.

    Designed parameters of a transformer/inductor TopClick here to try Online Magnetics Builder (design tool) now

    designed parameter for transformer
    User can fill in checking parameter, e.g. DC resistance, Magnetizing Inductance and Leakage Inductance, for IQC. Once the check box is clicked, the value between the corresponding pins is enabled for inspection. Simulated value is recommended but user can change the actual IQC specification by change wording in the corresponding text box.

    Change the testing details of Transformer/Inductor Drawing TopClick here to try Online Magnetics Builder (design tool) now

    fill in testing details
    User can fill in the testing details in the bottom of Transformer Drawing interface.


    Different type of bobbin can be selected TopClick here to try Online Magnetics Builder (design tool) now

    click to select bobbin
    User press “Select Bobbin” at the top-right side and will see the following page.

    different bobbin type
    Click on the picture to select bobbin type


    Change the number of pins of bobbin TopClick here to try Online Magnetics Builder (design tool) now

    select number of pin
    User can change the number of pins of bobbin there.

    Add/ delete fly pins TopClick here to try Online Magnetics Builder (design tool) now

    click to add fly pin
    In “Generate Drawing” page (section 7.8.44), user press “Add Fly Pins” at the top-right side and user can see the following page.

    click to add or delte fly pin
    User can add or delete fly pins pressing corresponding button


    Configure details of fly pins TopClick here to try Online Magnetics Builder (design tool) now

    modify fly pin details
    After adding fly pins (section 7.8.44.5), you can modify the detail of the fly pin or delete the corresponding fly pin by pressing “X”.

    Define the termination pins of a winding TopClick here to try Online Magnetics Builder (design tool) now

    click to define termination o a winding
    Press the number button can open an interface that can define the termination of a winding.

    set fly pin termination
    User can click one or more of the pins or fly pins available.


    Preview the Transformer/Inductor drawing page TopClick here to try Online Magnetics Builder (design tool) now

    The 'Preview' button at the bottom can open a preview page of the transformer drawing.

    transformer drawing preview