DC Choke Design Calculator

This design sheet is optimized for DC inductor design utilizing E-cores.  The core data used in this sheet are based on the Micrometals iron powder cores.  More core cores will be available soon.  The wire AWG selected for a given design based on the current capacity for conductors as specified by the National Electric Code (NEC) and the Underwriters laboratory (UL).  If you have any comments or questions regarding this design sheet or any future plans, please e-mail us.

The input design parameters required are:

Based on these design parameters, the program calculates a minimum window area product (AP) and a core must be selected with an AP which is larger the minimum value specified.

Design procedure:

• Enter the design parameters specified in the above table
• Select the desired operating current density and window utilization factor for the design (default values are J=400A/cm², K_w=0.4)
• Hit the "Calculate AP" button.  This will give you the minimum AP required (Window area product in cm⁴).  After a couple of seconds, the Select Core tab will become the active tab.
• Select a core from the database using the drop down list with AP greater than the minimum value given in 3.
• Select a corresponding core material typeHit the design button.  After a couple of seconds, the Design Results tab will become the active tab and all the design data will be listed.
• You can refine your design by changing the core type and the core material to optimize total losses and temperature rise.  Just reselect a core and re specify the core material and hit the design button to see the new values