In the realm of electronic components, innovation continues to push the boundaries of efficiency, performance, and versatility. Wurth Elektronik, a prominent player in the field, has taken a significant step forward with the expansion of their WE-TORPFC inductor series. This expansion adds 17 new parts to the series, ushering in a new era of possibilities for power electronics applications.
At the heart of this advancement lies the utilization of toroidal inductors, a crucial component in power conversion circuits. What sets these inductors apart is their tailored design for continuous conduction mode Boost converters, leveraging a concept known as continuous-conduction mode (CCM). This innovative approach allows these toroidal inductors to generate power outputs of up to several kilowatts, making them ideal for applications requiring substantial power delivery.
Traditionally, in power factor correction (PFC) inductors, winding losses and cooling efficiency have been points of concern. However, Wurth Elektronik’s newly introduced series has tackled these challenges head-on. Instead of the conventional bobbin-wound windings, this series adopts flat wire windings. This switch not only results in lower winding losses but also significantly improves cooling capabilities. The combination of reduced losses and enhanced cooling translates to greater efficiency and reliability in power conversion processes.
An area of paramount importance in power electronics is temperature tolerance. The WE-TORPFC series addresses this concern by being engineered to withstand temperatures of up to 155 degrees Celsius. Moreover, these toroidal inductors exhibit remarkable compatibility with operating voltages of up to 1000VDC, making them adaptable to a wide range of applications.
Diversity is a hallmark of this series, evident in its availability in multiple sizes. With inductances ranging from 118 to 720 microhenries (uH) and current ratings reaching up to 48 amperes (A), these inductors can seamlessly integrate into various systems. This adaptability positions the series for applications such as active power factor correction, industrial AC/DC inverters, solar inverters, and beyond.
In addition to its performance capabilities, the WE-TORPFC series undergoes rigorous testing to ensure reliability. AEC-Q200 reliability testing is conducted on the series’ mounting system, providing an extra layer of confidence in its robustness and durability.
As technology advances and demands for higher efficiency and performance increase, Wurth Elektronik’s latest innovation arrives at an opportune time. The expanded WE-TORPFC inductor series presents engineers and designers with a valuable toolset to enhance their power conversion solutions. Whether it’s in the realm of industrial automation, renewable energy, or other cutting-edge applications, this series paves the way for improved power management and more efficient energy utilization.
What is Continuous-Conduction Mode (CCM)?
Continuous-Conduction Mode (CCM) is an operating mode in power electronics used by switching converters such as Boost, Buck and Buck-Boost converters to alter the voltage level of DC power sources for purposes such as voltage regulation, power factor correction or energy conversion in electronic devices.
CCM stands out from Discontinuous-Conduction Mode (DCM) by never dropping below zero during a switching cycle, meaning inductor current continues to flow continuously despite any drops that might happen at some point during switching. By contrast, in CCM inductor current never dwindles to zero, thus giving rise to its name “continuous conduction.” Compared with DCM which sees inductor current dropping down below zero during some point during switching, CCM always remains continuous conduction.
Here is a more in-depth explanation of Continuous Conduction Mode:
Inductor Current Behavior: With CCM, inductor current fluctuates up and down during every switching cycle without ever reaching zero; this ensures a more uniform current waveform.
Switching Frequency: The switching frequency of a converter must be high enough so that inductor current has enough time to decrease gradually but not reach zero during each switching cycle.
Steady-State Operation: CCM is ideal for applications that require consistent or continuous power delivery. This mode works when load demand remains relatively constant without dropping to very low levels.
Voltage and Current Waveforms: Voltage and current waveforms in CCM tend to be more sinusoidal and predictable compared to those produced by DCM, where there can be intervals with no inductor current at all.
Benefits and Challenges of CCM: CCM typically provides better control of output voltage while decreasing voltage ripple, but may require more complex control schemes in order to regulate inductor current appropriately.
Efficiency and Losses: With CCM, inductor current remains nonzero to minimize core saturation in an inductor and therefore improve efficiency while simultaneously decreasing magnetic component losses. This leads to improved efficiency as well as lower magnetic component losses.
Applications: CCM is often utilized in applications where continuous power transfer is vital, such as voltage regulators, power factor correction circuits and applications with relatively stable loads.
Note that selecting either CCM or DCM depends on the specific needs and requirements of your application, such as load variation, efficiency goals and voltage ripple tolerance. Designers must assess each application carefully to select an operating mode which best meets its performance and efficiency objectives.