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Table of Contents
Design Parameters
1. Power rating
2. Voltage levels (primary and secondary)
3. Currents on both sides
4. Primary and secondary coils wire diameter/size
5. Iron Core area
6. Numbers of turns (primary and secondary)
We are going to design a 50 VA step down transformer of 230V to 12V. Necessary calculations
along with formulae are given below in details:
As we are going to design small transformer (of small power rating) so we are neglecting core and
copper losses as they doesn’t matters in small transformers
(http://engineerexperiences.com/category/transformer)and seriously considered in designing power
transformers (high power rating transforms).
Calculations:
1. Core Calculations:
Ai = 1/4.44xfxBmxTe
So, we know the frequency of the power system. We need magnetic ux and turns per volts. For
designing a small transformer magnetic ux density is averagely taken as 1 to 1.2.
By putting values we will get the area of core.
Current density of copper wire is taken as 2.2 A / mm2 to 2.4 A/ mm2 (approximately).
So, putting values
F= 50 hz
Bm = 1.2 wb/m2
Te = 4 (turns per volts)
As, we are going to design a practical transformer
(http://engineerexperiences.com/category/transformer)so we must consider the core
available in market. The standard Bobbins available in market practically is 1”x1”, 1.25”x1.5”,
1.5”x1.5” and so on. We took nearest core area available to our calculation. We took bobbin of
2.25 inch2 (1.5”x1.5”) or 0.00145161 meter square. We have the core area. We can calculate
turns per volts using this area by following:
Putting f=50 hz; Bm = 1.2 wb/(m^2); Ai= 0.001451 m^2, we got:
So, Turns per volts are 2.6 Turns per volts. (http://engineerexperiences.com/turns-per-
volts-transformer-design.html)
Number of Turns:
Size of Conductor:
As we know that
As, for copper the current density is taken as 2.3 A per mm square So, for area of copper
conductor
From the standard American wire gauge table, we can choose wire of the same thickness. It can
be seen that it comes out that required primary side wire is of 27 gauge which can conduct
required current. (for AWG table Click here (http://www.powerstream.com/Wire_Size.htm))
Selection of wire can also be done by calculating primary current and by cross match the
standard table of copper wire according to their current handling capabilities.
Secondary voltage = Vs = 12 V
From the standard copper wire, table it can be seen that wire of this thickness is of 15 gauge. So
for secondary winding we need 15 gauge wire.
So,
Number of Turns:
Primary side:
So,
As,
area of primary conductor = 0.1 mm2
= (0.1 x 10 ^ -6) m2
Volume of copper wire = area x length
So,
So,
L2 = 0.1778 x 32
L2 = 6 m (approx.)
As,
area of primary conductor = 1.83 mm2 = (1.83 x 10 ^ -6) m2
———————————————————————————————————————
(https://i0.wp.com/lh3.googleusercontent.com/-
ZkfU3uUO96s/Vk1qeGyiVqI/AAAAAAAAAlg/tS1YlVeqW2M/s576-
Ic42/secondary.jpg?ssl=1)
At this point you have done the Calculations and you have the characteristics of transformer
components. Now, for making in hard form, see few easiest steps of hardware
implementation of calculations (http://engineerexperiences.com/hardware-design-.html):
Here is another article for transformer core optimization using Genetic Algorithm
(http://engineerexperiences.com/transformer-core-optimization-using-genetic-algorithm-
ga.html) – a heuristic method of optimization.
For any Queries and further Assistance, feel free to comment below and like our facebook page
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Hardware Implementation of
Transformer Step by Step
engineerexperiences.com
Transformer Ratio
engineerexperiences.com
Transformer Types
engineerexperiences.com
AC Voltage
Measurement
without Transformer
engineerexperiences.com
Introduction to
Transformer
engineerexperiences.com
Tachometer Using
Arduino and Hall
Effect Sensor
engineerexperiences.com
Introduction to Three
Phase Transformer
engineerexperiences.com
DESIGN AND
DESIGN AND
CONSTRUCTION
POWER INVERTER
engineerexperiences.com
Transformer Design
Turns per Volts
engineerexperiences.com
Introduction to
Genetic Algorithm
(GA
engineerexperiences.com
Ad 1. Electrical Transformer
2. Power Transformer
3. 1 Phase Transformer
Anonymous says:
May 1, 2019 at 5:22 pm (http://engineerexperiences.com/design-calculations.html#comment-
9848)
Reply →
noxuz says:
February 22, 2019 at 1:34 am (http://engineerexperiences.com/design-
calculations.html#comment-7004)
Hi, you are not taking into account the total mass of the core needed due to it’s
saturation of magnetic ux Bm
Reply →
Pingback: Calculations for Design Parameters of Transformer | Engineer Experiences –
zliberate (https://zliberate.wordpress.com/2019/02/21/calculations-for-design-
parameters-of-transformer-engineer-experiences/)
I was looking for formulas to calculate transformar for example i have transformar
but i want to rewind it with di erent input and output ac. i couldn’t get formulas
for it please
Reply →
Basant
Reply →
M Adnan says:
November 6, 2018 at 8:20 pm (http://engineerexperiences.com/design-
calculations.html#comment-587)
Reply →
G. says:
September 27, 2018 at 12:17 pm (http://engineerexperiences.com/design-
calculations.html#comment-561)
You give formula parameters to use that do NOT make any sense then you solve
an equation BUT DO NOT Explain how you derived at simpli ed variable sub totals
and then give a resultant. For example: F= 50 hz
Bm = 1.2 wb/m2
Te = 4 (turns per volts)
Ai= 9.384 × 10-4m 2 ~1.45 inch sq. Really? Are you assuming your viewing
audience has taken advanced algebra or is space as a premium you can’t explain
how you did this or are you just too damn lazy to explain how you got there?
AS the saying goes —-it’s like listening to one engineer talk another.
Reply →
Mircea says:
September 27, 2018 at 1:40 pm (http://engineerexperiences.com/design-
calculations.html#comment-562)
Reply →
Anonymous says:
July 16, 2018 at 12:29 pm (http://engineerexperiences.com/design-calculations.html#comment-
515)
hello sir can you make also a calculation for toroidal transformer?
Reply →
Reply →
g.satheeshkumar says:
December 4, 2018 at 10:58 am
(http://engineerexperiences.com/design-
calculations.html#comment-998)
sir, you are put the value of Te=4, please explain this
brie y. and next stage u derive this as 2.6 turns. how u
adapt the Ai value with this formula Te=1/4.44fABm.
Reply →
Reply →
g.satheeshkumar says:
December 4, 2018 at 11:09 am
(http://engineerexperiences.com/design-
calculations.html#comment-1000)
Reply →
Anonymous says:
July 16, 2018 at 12:18 pm (http://engineerexperiences.com/design-calculations.html#comment-
514)
Hello sir, can i apply this on SWG magnetic wire? We dont use here in philippines
AWG table. There is a big di erence on AWG ang SWG
Thank you
Reply →
Asad Ullah says:
July 28, 2018 at 9:24 pm (http://engineerexperiences.com/design-
calculations.html#comment-516)
Reply →
Reply →
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Anonymous says:
December 2, 2018 at 5:07 pm (http://engineerexperiences.com/design-
calculations.html#comment-933)
Reply →
Den says:
June 18, 2018 at 8:46 pm (http://engineerexperiences.com/design-calculations.html#comment-
495)
Anyone knows why the e ciency e ect is only applied on primary current ?? How
about the secondary current?
And also what should I do if I require 50% margin for core area? Why is also the
perimeter value is using 1.75 instead of 1.5??
Reply →
Reply →
1.75 is not wrong (to some level). As we are not taking other
parameters into account for winding. So, Doesn’t matter here (to
this level of design)
Reply →
Olajide Taiwo says:
June 15, 2018 at 5:34 am (http://engineerexperiences.com/design-calculations.html#comment-
493)
Thank you for your design of this single phase transformer, all your explanations
are very clear and straight to the point.
It will be very nice if you could please let us have also a design for a three phase
transformer.
Thanks a lot.
Jide T.
Reply →
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Mircea Bujor says:
June 4, 2018 at 7:55 pm (http://engineerexperiences.com/design-calculations.html#comment-
490)
Reply →
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Tebogo says:
May 18, 2018 at 12:34 pm (http://engineerexperiences.com/design-
calculations.html#comment-478)
Reply →
Reply →
Tebogo says:
May 18, 2018 at 12:17 pm (http://engineerexperiences.com/design-
calculations.html#comment-477)
Sir what is the shape of this bobbin and which side are you referring to since we
used a 1.5inchx1.5inch bobbin?
Reply →
http://engineerexperiences.com/hardware-design-.html
(http://engineerexperiences.com/hardware-design-.html)
hope this link will help you.
Reply →
Reply →
Anonymous says:
May 13, 2018 at 9:01 pm (http://engineerexperiences.com/design-calculations.html#comment-
475)
GREAT sir!
Reply →
Above Calculation based on the Value Te=4 Turn Per Volt. What is
bene t/drawback if we choose a big/small size of Bobbin
Reply →
Reply →
Munawar says:
April 15, 2018 at 7:36 am (http://engineerexperiences.com/design-calculations.html#comment-
454)
Reply →
Asad Ullah says:
April 16, 2018 at 11:09 pm (http://engineerexperiences.com/design-
calculations.html#comment-456)
Reply →
Reply →
Just follow the formula given above. Nothing will change except
the power ratings. Two windings of same ratings with be there on
secondary side.
Reply →
sir, can the size of the copper wire a ect the number of turns? if it can, how so?
because, as how I understand the solution above, it seems it does not a ect.
sorry, I’m a newbie. and moreover, we would like to design a 15VA, 220/30 V single
phase transformer. we already have 1.25″x1.25″ bobbin and a number 25 gauge
wire. how can we determine the number of turns?
Reply →
Asad Ullah says:
April 16, 2018 at 11:44 pm (http://engineerexperiences.com/design-
calculations.html#comment-461)
Reply →
Santosh says:
March 22, 2018 at 9:12 am (http://engineerexperiences.com/design-
calculations.html#comment-434)
Sir mai 5kva 8no. Core me(input=90v – 300v) automatic stabilizer banana chahata
hu to sir mai kaise calculate kr k turn nikalu.
Reply →
Calculate turn and wire gauge for each voltage level at secondary.
Obviously, you want some steps between these voltage levels so
there will be as much number of windings as the number of steps
of voltages of secondary. Then by the use of relays, voltage sensor
and micro-controller programming, you can make this automatic.
Reply →
Santosh says:
March 22, 2018 at 9:05 am (http://engineerexperiences.com/design-
calculations.html#comment-433)
Sir mere paas 7no. core(2″ * 5″) hai to sir mai (input= 90v-300v) tk ka automatic
voltage stabilizer ka coil banana chahata hu.
to sir mai kaise calculate kr k turn nikalu.
Plzz bataeye.
Reply →
Anonymous says:
March 12, 2018 at 12:46 pm (http://engineerexperiences.com/design-
calculations.html#comment-431)
Reply →
http://engineerexperiences.com/transformer-basics.html
(http://engineerexperiences.com/transformer-basics.html)
Hope you can nd enough to understand here.
Reply →
Thanks for this simple explanation. I am an eighty year old man retired and going
through these things just to while away the time. I have some engineering
background. But have forgotten everything- practically. Thanks once again.
Regards, Guptan
Reply →
Ralph says:
February 18, 2018 at 7:54 pm (http://engineerexperiences.com/design-
calculations.html#comment-421)
Does this applicable for multi-winding transformers with di erent voltage and
current rating in every windings.
Reply →
Reply →
sir , what is pulse transformer & how to make it .for fence charger input 350-400
volt & output 5000-9000 volt in pulse with 8 mill ampere
Reply →
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Anonymous says:
December 28, 2017 at 8:18 pm (http://engineerexperiences.com/design-
calculations.html#comment-400)
Reply →
Reply →
Reply →
F= 50 hz
Bm = 1.2 wb/m2
Te = 4 (turns per volts)
How did u get te =4 turns per volt?
Reply →
Reply →
inayat says:
October 7, 2017 at 1:23 pm (http://engineerexperiences.com/design-
calculations.html#comment-351)
Reply →
Reply →
PHIWE (http://engineerexperiences.com) says:
October 5, 2017 at 1:23 am (http://engineerexperiences.com/design-
calculations.html#comment-350)
Reply →
Reply →
Sir ma transformer banana chatha ho mera pas iron core pare ha his ma
3.8cm5cm ha moja wire no bata dena tarn me tadad be secondary or prembry
Dino ma ma an pard ho koch moskil aya gee please ap mer madad kro thanks
Reply →
Reply →
Asad, This page is absolutely fantastic. Thank you very much. In the above, “1.75 is
the length of one side of the bobbin.” In the example on this page, I understood
that a standard size of 1.5 inches by 1.5 inches was used for the example
calculations. Could you please help me understand where the 1.75 inches is
derived from?
Reply →
Sir,I made a transformer 24V 3A,72VA operated in 220V which heated more
without load..and output is accurate, bobbin area is 10.26sqcm , primary turn 937
, turn per volt 4.26, secondary turn 106 ,primary wire gauge 28, secondary wire
gauge 19 can anyone please explain why so heated?????thanks
Reply →
Reply →
Bobby says:
August 12, 2017 at 10:42 pm (http://engineerexperiences.com/design-
calculations.html#comment-305)
pls for large transformer power like 6kva, how will i get the value of ux density
(Bm)
Reply →
Amabo says:
August 8, 2017 at 9:28 pm (http://engineerexperiences.com/design-
calculations.html#comment-301)
By using the same perimeter value for both primary and secondary, you implicitly
assume that windings are side by side (split bobbin) rather than one over the
other. Standard practice is to use not perimeter but mean length of term (MLT),
thus the stated wire lengths are too long. The winding area is not lled 100%
because the wire is round and has air included in the winding cross section.
Standard practice is to use a ll factor which tends to be around 60% when
winding technique and insulation thickness are included. This a ects the choice of
wire gauge to t the cross section. From wire length and gauge the next step is to
calculate resistances from which the voltage drops can be known, noting that AC
resistance will be somewhat greater than DC resistance. Then the design can be
iterated to compensate.
Reply →
Yes you are right. I am aware of ‘mean length per turn’, ‘window
e ective area’, resistance of winding, core geometrical constants
and many more factors according to which transformer is
designed. Here, we have designed small transformer and with
compensation factor, some parameters are neglected and some
are included in compensation factor.
Thank you for your considerations. Design calculations according
to all these factor included will be available soon.
Reply →
behzad says:
July 29, 2017 at 3:32 am (http://engineerexperiences.com/design-calculations.html#comment-
291)
as i gured out, all the formulas work only for ac input. what about a rectangular
pulse? should i use Fourier expression o voltage and then nd EMF equation?
Reply →
Reply →
Anonymous says:
July 20, 2017 at 1:26 am (http://engineerexperiences.com/design-calculations.html#comment-
277)
Reply →
Mr Asad thank you for your explanation. Please I have a problem similar to this…
am asked to nd the parameters of a Transformer core (shell type) such as
height(H), diameter(D), width(W), width and length of the window slot(Ws). Haven
being given insulation thickness as 2mm, V=220/18v, P=450W, power factor as 0.8,
window factor as 0.3, maximum ux density(Bm=0.42T), F=50Hz, k=1.2.
Please how can I go about this.
Reply →
What is current density for aluminium? Is the current density value is xed?
Reply →
Asad Ullah says:
July 10, 2017 at 9:31 pm (http://engineerexperiences.com/design-
calculations.html#comment-267)
Reply →
Reply →
bobbin of 2.25 inch2 (1.5”x1.5”) or 0.00145161 meter square. how dis you get
0,00145161!
Reply →
Reply →
syed says:
June 13, 2017 at 10:04 am (http://engineerexperiences.com/design-
calculations.html#comment-252)
asslamwalkum sir can i u please explaine me the core calculation of CT
Reply →
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Thank you for explaining the design of transform. I have one confusion that
Perimeter of bobbin=1.75 * 4 you have taken but 1.75 where it comes from???
Reply →
Reply →
Syed Hedayat Hussain Zaidi says:
April 5, 2017 at 4:05 pm (http://engineerexperiences.com/design-calculations.html#comment-
217)
Dear Mr. Asad-ullah Sahab. Your Article is very informative and help full. thanks
for sharing it. Regards, May Allah live you long..
Reply →
Idrees says:
April 2, 2017 at 9:05 pm (http://engineerexperiences.com/design-calculations.html#comment-
212)
Reply →
Akos says:
March 15, 2017 at 4:22 pm (http://engineerexperiences.com/design-
calculations.html#comment-172)
When you calculate the core area you assumed Te = 4 (turns per volts) but it was
not clear where this number 4 comes from. In other calculations the core area is
proportional to the squareroot of VA and approximated as Ai = 1.152*sqrt(Output
voltage x output current) = 1.152*sqrt(50VA) = 8.146 cm^2=8.146*10^-4 m^2 and
then using this Ai value the turns per volt is calculated Te = 1/(4.44AiBf) = 1/(4.44 *
8.146*10^-4m^2 * 1.2T * 50Hz) = 4.6 turns per volts which is close to 4 that you
assumed. So actually the turns per volts come from the area and not in the other
way because the are comes from the VA. So we don’t have to assume anything
because everything comes from somewhere.
Apart from this your work is nice. That was the only thing that was not
understandable and i had to look it up. Thanks for your post.
Reply →
That’s good thing you took interest and did research in this. But if
you look into literature of transformer design, some parameters
are constant for speci c core size and speci c material. You can
nd standard tables in many books which give you constant
values for calculated core sizes. This 4 turns per volt is from
standard table for small transformer design calculation listed in
Book by “R.K Agarwal” under the title of ” Principles of Electric
Machine Design”
Reply →
for design purpose how much power factor will take for distrubution transformer
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dhanasekar S says:
February 4, 2017 at 11:38 am (http://engineerexperiences.com/design-
calculations.html#comment-128)
Reply →
Reply →
Almas (http://engineerexperiences.com/design-calculations.html)
says:
February 3, 2017 at 3:15 pm (http://engineerexperiences.com/design-
calculations.html#comment-127)
Reply →
Reply →
Almas
(http://engineerexperiences.com/design-
calculations.html) says:
February 7, 2017 at 12:02 pm
(http://engineerexperiences.com/design-
calculations.html#comment-135)
Reply →
I want calculations for low watts . Ma transformer is pri 220v /sec 1000v and
current is 50 ma .
Second transformer is pri 400v sec 5 v and current is 5 ma …can you help me
Reply →
Calculations for the wire would be same as for others. If you don’t
nd wire of your desire rating, use smallest ( say 30 AWG wire) to
wound your transformer. Your rst transformer is of course falls
in category of high voltage so lamination precautions must be
followed. Likewise, you can design second transformer.
Reply →
loganathan says:
January 2, 2017 at 4:36 pm (http://engineerexperiences.com/design-
calculations.html#comment-116)
hi… thank u for this article. upto which power rating core & copper losses r
neglected..
Reply →
Reply →
Andrew says:
December 23, 2016 at 3:13 am (http://engineerexperiences.com/design-
calculations.html#comment-111)
Hi, thank you for your article. On the core calculations section, could you explain
where you got the 4 turns per volt from that is needed to plug into the equation to
calculate the core area. Also, in the same equation, the constant 4.44 – what does
this represent? Thank you
Reply →
Asad Ullah says:
December 25, 2016 at 8:55 am (http://engineerexperiences.com/design-
calculations.html#comment-112)
Reply →
nervic says:
February 7, 2017 at 5:17 pm (http://engineerexperiences.com/design-
calculations.html#comment-136)
Reply →
Hey just wanted to say thanks you for all of these great articles! They read very
very well and you’ve covered all of my questions.
Reply →
Great… Thanks.
Reply →
ishtiaq says:
October 27, 2016 at 10:59 pm (http://engineerexperiences.com/design-
calculations.html#comment-29)
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