INTELLIGENT INDUCTOR SOLUTIONS

FULL SERVICE FOR HIGHLY EFFICIENT INDUCTORS

We provide customized inductor & high frequency material solutions – from design to prototyping and validation.

 

// Meeting your required performance

// Highly compact inductor solutions

// Shortend development cycle

 

COOLING TUNNEL TECHNOLOGY (CTT):


The Alvier Mechatronics developed Cooling Tunnel Technology (CTT)
provides up to 55% temperature reduction
and is integrable with all existing system cooling solutions

Power portfolio: Inductor

  • < 1000V​
  • Inductor development up to 100kHz for power electronic applications, e.g. DC/DC Converter, Inverter, On/Off-board charger
  • High frequency material solutions
  • Developed innovations: e.g. integrated Cooling Tunnel Technology (CTT)

CASE STUDY

Comparison between basic and advanced design:
COOLING TUNNEL TECHNOLOGY (CTT)

COMPARISON MADE WITH:

 

// Same winding and core

// Same electrical input (9,6 Arms@20kHz)

// Heatsink temperature 35°C

 

 

  • Features: Core + winding

  • Mounting: Horizontal
  • Dimensions: 70mm Dia. × 40mm
  • Material weigth

    • Copper: 200g
    • Magnetic core: 550g
    • Epoxy: 25g
    • CTT (Aluminum): –
  • Cooling: Blocked Unidirectional

  • Winding loss: 4W 

  • Core loss: 10W 

 

  • Features: Core + winding + Cooling Tunnel Technology

  • Mounting: Vertical or Horizontal
  • Dimensions: 75mm Dia. × 43mm
  • Material weight

    • Copper: 200g
    • Magnetic core: 550g
    • Epoxy: 25g
    • CTT (Aluminum): 100g
  • Cooling: Free Bidirectional​

  • Winding loss: 4W 

  • Core loss: 10W 
  • CTT loss: 0,4W

OUTCOME:

Due to our recently developed integrated Cooling Tunnel Technology (CTT) we are able to realize less temperature within the same dimensions.

Finally this leads to a temperature reduction up to 55% in comparison to the basic inductor design.

Experimental verification

Application: Active power filter unit

Inductor Design

To validate our simulation results we have built up inductor prototypes with and without CTT. In the test environment – an active power filter unit – we have measured the performance and the temperature of the single components.­

Application: Active power filter unit

Without CTT and aluminum housing

Basic design without the new Cooling Tunnel Technology shows a temperature about 98,3°C.

Application: Active power filter unit

Inductors including CTT

T1: Vertical mounted – with aluminum housing, shows a temperature about 68,1°C.

T3: Horizontal mounted – with aluminum housing, shows a temperature about 67,6°C.

// Both inductors show ~30°C less temperature than the inductor without CTT

Frequently asked questions about inductors and cooling systems

 

Why do higher switching frequencies require new inductor cooling solutions?

  • With higher switching frequencies the percentage of core loss will increase and will become the thermal and therefore sizing bottleneck – what results in higher costs. 

How Alvier Mechatronics' CTT solves this challenge?

  • Alvier Mechatronics' developed Cooling Tunnel Technology decouples the electrical and thermal design and provides free passage to the heat flux. 

Is the CTT integrable with existing system cooling solutions?

  • Yes! It can be integrated with existing solutions, also to improve the performance.

Will the CTT increase the costs?

  • No! It even lowers the costs because less of the more expensive core and winding materials are needed by the replacement through aluminum CTT.

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POWERED BY ALVIER MECHATRONICS

 

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Senior Electromagnetic Specialist for Energy Conversion and Magnetic Materials Characterization

Tushar Batra

"With Alvier Mechatronics' Cooling Tunnel Technology, temperature reduction for inductors is realized up to 55% with near zero effect on magnetic performance. Furthermore, the technology is integrable with existing waterplate and heatsink based cooling solutions."