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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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."