Why PQ ?

PQ cores among the best design for EMI reduction -necessary to meet restrictions Large surface area compared to volume allows for better heat dissipation Disadvantage-more expensive design

Why ferrite ? fewer turns needed on primary better coupling lower permeability low flux density-allows for quicker resetting in this application, DC saturation not a big issue HIGH EFFICIENCY

Temperature C vs. Normalized Power Loss

Temperature (C) vs. Permeability

Transformer Design

Transformer Design : Basic Constraints

Transformer Design : Basic Constraints

Transformer Design : Basic Constraints

Transformer Design : Optimizing Constraints

Transformer Design : Optimizing Constraints

Transformer Design : Optimizing Constraints

Transformer Design : Optimizing Constraints

Transformer Design : Core Geometrical Constant

Transformer Design : Calculation of

p for winding material fixed Copper 1.68 * 10^(-8) as mentioned before is around 0.3 = V.sec = 220/50 Ipri was given. Taking it to be 0.5. Itot comes out to be 1. For designing a transformer of 97% efficiency = > Losses total will be around 3.3W. (Assuming pf 1) As mentioned For ferrite cores is 2.6. is around (24.7)*50/15000*1.4.

Transformer Design :Selection of core

Kgfe calculated from the given parameters comes to be around 126.3*10^(-3) We can use the following cores(dimensions) now as per our requirements and cost.

Transformer Design : Selection of Core

Transformer Design : Design Procedure

We generally prefer Etype core. Now, we have got the values of all core variables.

Calculating ^B according to this gives ^B = 11.06 T

Transformer Design : Design Procedure

n Comes out to be 614 turns. n Comes out to be 61 turns.

1 2

Transformer Design : Design Procedure

comes out to be 0.5. comes out to be 0.5. comes out to be 7.9 * (10^(-4)) comes out to be 7.9 * (10^(-3)) AWG 28 AWG 18

Day by Day Design Progress Day 1

220/22 V. 4A primary current. 99% efficiency Primary : Area-1.77 * 10^(-4), 8600 Turns Primary : Area-1.77 * 10^(-4), 860 Turns Coil area : 4.24 Winding area : 8.92 Mean length per turn : 12.0 Magnetic Path Length : 8
Changes/Errors in Design: -> We recalculated the design parameters realizing that the value of core loss coefficient taken by us was wrong. -> We also realized that the core design parameters were not practical to be realized.

Day by Day Design Progress

Day 2
220/22 V. 4A primary current. 97% efficiency Primary : AWG = 28, 1242 Turns Secondary : AWG =14, 124 Turns EE70 ferrite type core Coil area : 3.24 Winding area : 6.75 Mean length per turn : 14.0 Magnetic Path Length : 9

Suggestions and Recommendations by Sir : -> The current taken was very large, hence very large kVA rating, this was improved.

Day by Day Design Progress

Day 3
220/22 V. 0.5A primary current. 97% efficiency Primary : AWG = 28, 614 Turns Secondary : AWG =14, 61 Turns EE70 ferrite type core Coil area : 3.24 Winding area : 6.75 Mean length per turn : 14.0 Magnetic Path Length : 9

Suggestions and Recommendations by Sir : -> Instead of ferrite core make transformer by using silicon steel material and then check the efficiency.

A transformer's coils can be wound with either copper or aluminum conductors. For equivalent electrical and mechanical performance, aluminum-wound transformers usually cost less than copper-wound units. Because copper is a better conductor, a copper-wound transformer can be at times slightly smaller than its aluminum counterpart, for transformers with equivalent electrical ratings, because the copper conductor windings will be smaller. Coils made of copper wires have slightly higher mechanical strength. With both materials, the winding process and the application of insulation are the same. Connections to the terminals are welded or brazed. We have used copper in our designing of transformer.