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)
enables up to 55% temperature reduction and downsizing.
CTT 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)
SPECIAL EFFECT
Clever downsizing thanks to cooling!
With the Cooling Tunnel Technology (CTT) the temperature of components can be drastically reduced. This effect enables the possibility to downsize the component without heating effect. In the end it is just your choice if you want to keep the size and cool down the component or if you want to decrease the size without higher temperature in the system.
Same size. Lower temperature.
OR
Same temperature, smaller component = Downsizing
// DOWNSIZE WITHOUT TEMPERATURE INCREASE!
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."