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Calculations for design parameters of transformer pdf

Academia.edu use cookies to customize content, tailor ads, and improve the user experience. By using our website, you agree to our collection of information using cookies. To learn more, see our Privacy Policy.× Thousands of finished off-the-shelf transformers out on the market are available to be designed for electronic or electrical
circuits. But when the right part just can't be found, consider designing a custom transformer to suit your specific requirements. You have to determine a few things before you can start designing a transformer, though. These include at least the input voltage(s) and the frequency and output voltage(s) and the current(s). There may well be
other parameters to consider, both physical and electrical, such as free space for mounting, mounting style, insulation requirements, leakage currents, etc. Environmental issues can also be a consideration. Note: At this stage, it is important to point out that all the decisions made regarding the design will be verified through calculations
that can only be made according to many rules of thumb' and educated guesses used to get us to this point. Choosing the kernel The first step is to determine the type of kernel for the design. You should consult with a core manufacturer to get the specific properties and power management features for each core type and size. However,
a general starting point is: • When less than 400 Hz is less than 400 Hz, a lamination of silicon steel is used in general. • At 400 to 2000 Hz you should consider a tape-wound or nickel-allwing core. • Over 2000 Hz, look at ferrite. Remember this is only a guideline; it is not uncommon to go outside these ranges (e.g. sound transformers can
use silicon steel laminates and operate from 20 to 20,000 Hz). There are many other core types and many sizes, shapes and material qualities within the cores listed above. The exact core selected may depend on table spacing, position, mounting style or a series of physical and electrical parameters that only you can determine. Most
core types also need a twisted coil that fits the core you choose and possibly help with the installation of the finished product. Make sure that there is sufficient coil style and material available and that you have all the mechanical measurements to determine winding details later in the design. Certain cores do not require a coil, but we save
them for a different discussion. After selecting a kernel and coil, calculate the correct number of primary turns to use using formula 1 or 2 (see Basic design formulas below). There are several variables to consider when using these formulas. You will need to consult the key manufacturer's data for answers to specifications such as flux
density and stacking factor. 1) N(p) (V x 108) / (4.44 B A f K) sinusbølge 2) 2) = (V x 108) / (4 B A f K) square wave 3) N(s) = V(s) / V(p) x N(p) 4) I(p) = (VA(s) + loss) / V(p) 5) I(s) = P(out) / V(out) 6) Open circuit voltage (Voc) = N(s)/N(p) x V(p) 7) Loaded voltage (Vld) = Voc-[IR(sec) + (IR(pri)) x (N(s)/N(p))] 8) Temp rise (T(C)) =
(loss/(0,008 x surface area)) N(p) = Primary revolutions N(s) = Secondary turns B = Flux density in gaus ' A = Core range in centimeters squared f = Frequency K = Stacking Factor L = Induction A(l) = Inductance per turn squared for a given core Windings and Wire The primary winding current and wire size must be determined. The
primary current will be equal to the total output power plus transformer power loss divided by the primary voltage. For power loss, I start at a 10% increase in input power, assuming a 90% effective transformer. For example, a transformer with a 12-V, 2-A output at 120 V input would be: 12 V x 2 A = 24 VA; 24 VA x 1.10 (110%) = 26.4 VA
needed in primary winding; 26.4 VA/120 V = 0.22 A in primary winding The next step will be subject to debate and adjustment depending on the characteristics of the transformer: I generally start at approximately 500 circular mills (cm) per amp to select the starting threader. This number may be smaller for small transformers and larger
for large transformers. this decision is again up to the designer. Using the example above, 0.22 A x 500cm/A = 110cm; I would start with a 29 gauge wire (127.7cm) for the primary. You must now determine the number of turns required for each secondary winding. The first step is to use formula 3 (N(s) = V(s) / V(p) x N(p)) to determine
the turns to a perfect transformer. This number must then be increased to account for the losses in the coils. As a rule of thumb again, I start with a 10% increase in the number of turns, assuming a 90% effective transformer: N (r) x 1.10 = N Turns. This percentage varies depending on the characteristics of the design. Use the same
method to determine the secondary gauge(s) that you used for the primary. This simple view of a winding coil shows the dimensions that will be needed for the winding area. Now you need to see if the windings fit into your winding area and determine the actual loss of the coils. Start by determining the winding width of the coil (ww), the
winding height (wh) of the coil and the average length of revolutions (mlt) from the mechanical drawing (see figure). With this information, you can now calculate how many twists of thread can fit in each layer of winding for each winding. Then, determine how many layers of each wire gauge are used, it will take to wither the calculated
number of turns for each given winding. Finally, calculate the total height of all the viktninger wounds concentrically. Remember to include the insulation used between the windings in calculating your total winding Confirmation The next step is to confirm your design. Will it fit into the allowable winding height with enough play to allow for
errors? Remember that the windings will not be perfectly layered, so you should allow for some bending of copper wire as it bends around every corner of the coil. I use a maximum of 85% fill (or build) when comparing the actual winding height to the allowed coil winding height: (Actual winding height/allowed winding height) × 100 =<
85% A build of about 75% is more desirable and will make the transformer easier to manufacture in the long run. Next, calculate the resistance of each winding and the loaded voltage losses in the winding to determine loaded output voltages. First, the resistance in each winding is calculated by multiplying the average turning length by
the number of revolutions. This gives the total length of the wire conductor. No matter what unit of measure you use, convert this length to thousands of feet (K ft); a length of 400 i/12000 = 0,03 K ft. Now from a magnet wire chart, you can get resistance of each gauge of wire in thousands of feet. For our example, the 29 gauge has a
resistance of 81.21 Ω/K ft, then a 400-in. wire would have a resistance of 0.03 K ft × 81.21 Ω/K ft = 2.44 Ω. When you have the resistance of a winding, simply calculate the voltage drop across this winding by multiplying the resistance with the current in the winding. In this primary it would be 2.44 Ω x 0.22 A = 0.540 V. Calculate the
voltage drop across each winding in the same way. The next step is to calculate the open-circuit voltage for each secondary using formula 6 and the loaded voltage using formula 7 of (see Basic Design Formulas). I put these together because I usually do both calculations on each secondary winding before moving on to more winding if I
have them. The most important thing to note here is that the primary voltage drop is reflected in the secondary strained voltage in the ratio of the swings. Then add it to the secondary voltage drop. The sum of the two is then deducted from the open circuit voltage of the given secondary. This gives you the loaded output voltage of this
secondary (I realize the formula could be mathematically simplified, but this format gives me easier use with a calculator, again, my opinion). If the voltage is not what you want, divide the desired output voltage by the calculated output for an error ratio. Use this ratio multiplied by the number of turns on the given secondary and recalculate
everything that starts at the number of layers of winding. Temp Calculations After calculating the swings, you must know the calculated temperature increase. There are two main reasons for temperature rise in a transformer: nuclear loss and winding power loss. See the manufacturer's data sheets and density used in your design.
Winding power loss is easily calculated by multiplying the voltage drop over the winding again with the current in the winding (I2R). The sum of power loss in victs, primary (e), and secondary (e) multiplied by 1.33 (I'll be honest, I don't quite know where this factor came from, but it has to do with heat transfer and concentric vikting, and it
works) to provide the overall effective heat loss of viktings. Add core loss to the twisted loss of total power diversion. To determine how well the transformer spreads power loss, we need to calculate the surface area of the finished unit. This just requires looking at all the surfaces that will be exposed to air and adding them up into inches
squared. Now use Formula 8 from the design formulas to calculate the transformer's estimated temperature increase. Once again, what constitutes an acceptable temperature increase depends on the application and the designer. I always use 50ºC as my maximum increase allowed. Keep in mind that forced air cooling or coolant can be
used in the end product, which may push this number higher. Now that you have made all your decisions about design aspects, based on rules of thumb and educated guesses, you should be able to confirm the choices made using formulas and calculations discussed in the article. If things somewhere along the way don't work, you have
to go back, make the necessary changes, and start over. This includes the calculation of the temperature increase. Calculation.

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