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CONSTRUCTION OF A TRANSFORMER

WHAT IS A TRANSFORMER?
An electrical component is designed to change the level of voltage and current, according to the specific requirements of the case. Formed by two coils wound around a common core or center. The core is formed by a predetermined number of sheets or foils made of an alloy of iron and silicon .This alloy reduces loss by hysteresis magnetic (ability to maintain a magnetic signal to be removed after a magnetic field) and increases the resistivity of iron.

USE AND APPLICATION OF PROCESSORS


The electric current generated in power plants, must be transported to homes and businesses. This requires using very high voltages in excess of 25,000 volts. For this reason every so transformers are used to convert the high voltage at 115 volts or 220 volts, depending on the country. Electronic devices for homes and industries used to operate at different voltage levels delivered by the public. To operate these devices require a transformer . This manual is intended simply, teaching how to build homemade transformers. As the market in some countries make it costly or difficult to purchase. This tutorial includes tables and formulas for the construction of all types of transformers that correspond to the needs of you and your market. NOTE : The transformer that we teach in this case is 44V x 44V AC, ideal for 250W amplifiers , but it is good to note that this is just one example. Every time you think make a transformer must first read the article Calculating transformers , until you learn well calculated.

Materials

Double layer magnet wire

The copper wire multipurpose is coated with a polyester resin based overcoat poliamidemida Imide and popularly known asDielectric Layer . coating Two types of HS (Single Layer) and HD (Double Layer). The magnet wire can be round, square or rectangular. Basic features : 200 degrees Celsius heat resistance, overload resistance, perfect for winding workability, abrasion resistance, dielectric strength when wet, resists thermal shock, the flow thermoplastic and solvents. This wire is used in the manufacture of generators, alternators, coils, electric motors,

ballasts, mercury lamps, power transformers, etc..To easily get the wire, you can resort to junkyards or second where recycling is achieved. The wire should be neither peeled nor burned, or partly, or about to break.

Silicon iron sheets

The plates or sheets of soft iron or silicon iron, are in the shape of letters ( R ) and ( E ) interspersed that form the core of the transformer. These come in grain oriented (more gauss) or non-oriented (common plate). This material is ideal to avoid losses by hysteresis magnetic and have the ability and demagnetized imanarse quickly and easily. Achieving these new plates are expensive because their manufacturers sell wholesale. Therefore we invite all interested to visit or cacharreras deposits, to recycle used transformer plates, if the recycler does not, you need to interest in the topic, offering to buy the plates and wire at a better price than if the recycler or scrap sold by weight. formaletas veneers and have a direct, each sheet exists for each formwork. Below is a table with the specifications of the most common market plates.

Drawing sheets for the transformer core

Dimensions in millimeters of the sheets to the core of the transformer

A 48 60 66 75

B 32 40 44 50

C 16 20 22 25

D 8 10 11 5.12

E 6.0

Weight-g Cm 120 190 225 300

84 96 114 132 150 180 210 240 300

56 64 76 88 100 120 140 160 200

28 32 38 44 50 60 70 80 100

14 16 19 22 25 30 35 40 50

7.0 8.0 8.0 8.0 9.5 9.5 11.0 11.0 11.0

365 480 675 900 1170 1680 2300 3000 4700

Waxed paper

When building a transformer, power is transmitted from the primary to the secondary winding, although these do not touch each other, because if it were to touch, should short circuit. waxed paper thickness gauge is used to isolate the windings or wire coils together. This paper, as its name implies, is a paraffin bath, which makes it flexible and ductile. Furthermore it seals out moisture and gives heat resistance, preventing crystallize. Failure to achieve the waxed paper, parchment paper can be used or butter fat, but their durability is not the same.

Formwork

The formwork is a square reel which is used as support for winding the wire and prevent spreading, helping the smooth engagement of the wire. At the time of manufacturing a transformer must take into account that the formwork sheet and are directly linked, and that the width of the center plate, determines the width of the formwork, and the quantity of sheets, determine the length of the formwork. It is therefore important when calculating the area of the core of the transformer, or build a search formaleta we approach this area and match the plates we have at hand. The Formaletas are available in plastic, cardboard and glass fiber (for large transformers).

The formwork are available in stores windings materials, although they are sometimes difficult to obtain. For this reason we have asked Jaime Rios , Professional Surveyor, to develop a straw cardboard formwork, with their plans, they can download for free here . Below is a table showing the most common formwork on the market, with its area, maximum power on the core and the number of turns per volt, to facilitate further construction of transformers used in sound.

Table formwork core


Measurement of nucleus area in centimeters. Compare the core area with the closest in the table, use this or the next larger area to which you need and the number of turns per volt, calculate the wire turns of the primary winding and secondary.

CORE

MAXIMUM POWER

Turns per volt

AREA Cm

1.6 x 1.9 2.2 x 2.8 2.5 x 1.8 2.5 x 2.8 2.8 x 1.5 2.8 x 2.5 2.8 x 3.5 2.8 x 5 3.2 x 3.5 3.2 x 4 3.2 x 5 3.8 x 4 3.8 x 5 3.8 x 6 3.8 x 7 3.8 x 8 3.8 x 9 3.8 x 10 3.8 x 11 3.8 x 12

9W 37W 20W 49W 17W 49W 96W 196W 125W 163W 256W 231W 361W 519W 707W 924W 1170W 1444W 1747W 2079W

14 7 9.3 6 10 6 4.3 3 3.75 3.3 2,625 2.76 2.21 1.85 1.58 1.38 1.22 1.1 1,004 0.921

4.3 6.16 4.5 7 4.2 7 9.8 14 2.11 8.12 16 2.15 19 8.22 6.26 4.30 34.2 38 41.8 45.6

4.4 x 9 4.4 x 10 4.4 x 11 4.4 x 12

1568W 1940W 2342W 2787W

1.6 0.95 0.867 0.795

39.6 44 48.4 52.8

Construction of the formwork for the transformer Formwork drawings

After choosing the formwork that is closest to your needs, print thePDF with the plans. Clquelas on a sheet of cardboard or pasteboard straw 1 millimeter thick, and then cut out with a scalpel, being careful to make as accurately as possible, since the formwork must receive therein the iron-silicon sheets, which must enter accurate, but not tight. In the PDF of the formwork , find seven planes that correspond to the processors used in our projects more audio, if you need a different formwork can make a scale from ours. To see the detail photo, click on it.

Formwork assembly

Here we see how to assemble the formwork methodological. The first thing is to make a square tube with the smallest rectangle to form the space containing plates. When you paste the second layer over the first, do the opposite, rendering them in opposite corners of the junction each layer, wherein the first, is embraced by the second layer, and give power and grip to the two pieces. Use wood glue and applied liberally. Then paste will double parts up and down, taking the form of reel. Then attach the other pieces of reinforcement as shown in the photos.

Reinforcement with masking tape

Formwork must be strengthened with masking tape, as the pressure to be received at the time of winding the wire, is quite strong. Try giving great firmness to the formwork. Then paint the formwork with Dielectric Layer.

FINDING THE TRANSFORMER FOR AMPLIFIER


TRANSFORMER

Electrical component having the ability to change the voltage level and current through two coils wound around a common core or center. The core is formed by a large number of plates or foils of an alloy of iron and silicon. This alloy reduces magnetic hysteresis losses (ability to maintain a magnetic signal to be removed after a magnetic field) and increases the resistivity of iron.

Operation

The change in voltage or current delivered by the transformer is reversed. When the transformer increases the voltage, low current, and when the voltage drops, the current rises. This leads to a law: the energy that delivers a transformer can not be greater than the energy that goes into it. Although

the primary and secondary winding are insulated by cardboard, waxed paper or plastic, the magnetic field between the two windings, transmits power from primary to secondary. There is a relationship between the turns of the primary winding and the secondary winding. This relationship determines the output voltage of the transformer are equal and the relationship between the turns of the windings and the input and output voltages. When the primary winding is equal to the secondary winding voltage and input current are equal the output voltage and current. These transformers are only intended for galvanic isolation, ie we can touch the output current without being electrocuted. Changing the turns of the secondary winding wire, change the output voltage of the transformer. Example: if for each turn of the primary winding, give three turns secondary, would, in the case of applying a voltage of 10 volts at the input, the output would be 30 volts. And we wind one turn of wire on the secondary to primary turns of three, in the case of applying a voltage to the input of 30 volts, the output would have to 10 volts.

Here's a practical method that allows to know the characteristics of the transformer to your amplifier. Actually there are many ways to assess and calculate a transformer, but all we will propose, leads easily and accurately to the transformer model we need. The starting point is to determine the power amplifier for each channel if stereo, for each of the two channels. Each channel contribute half of the power amplifier. We will see an example tienendo one 100-watt stereo amplifier , this means that each channel is 50 watts, or power is 50 watts per channel. It will use 8 ohm speakers, ie the speaker impedance RL is 8 ohms, determined by the manufacturer of the integrated circuit output. That is, the actual voltage ( RMS ) of the transformer for this amplifier is equal to the continuous voltage amplifier consumes divided by square root of 2 (1.4141). But prudence is advisable to increase the value obtained in two or volts. For example, your amplifier is powered by 34 volts DC , then the RMS voltage of the transformer is calculated as follows: V RMS = 34 / 2 Quel it is equal to: V = 24 volts RMS

These 24 volts is advisable add about 2 volts, as noted above, resulting in: V = 26 volts RMS The power transformer defines the dimension of the core.Power is not simply the product of the multiplication between the voltage and amperage of the transformer. Like this:

PT = V x I RMS RMS

For example in the previous case calculate a voltage of 24 volts ( RMS ) and a current of 5 amps, then the output will be: PT = 24 X 5 = 120 watts

Table AWG

Caliber 7 8 9 10 11 12 13 14 15 16 17 18 19

Circular Mils Diameter mm Amperage 20.818 16.509 13.090 10.383 8.234 6.530 5.178 4.107 3.257 2.583 2.048 1,624 1,288 3.67 3.26 2.91 2.59 2.30 2.5 1.83 1.63 1.45 1.29 1.15 1.2 0.91 44.2 33.3 25.26 22.21 16.16 15.13 15.10 8.3 6.6 5.2 4.1 3.2 2.6

The reason two volts increase, to provide a margin of loss in the diodes and in the resistance of the transformer. To respond adequately their transformer must be constructed with copper wire gauge appropriate to the amperage that will induce.

20 21 22 23 24

1.022 810.1 642.4 0.509 0.404

0.81 0.72 0.65 0.57 0.51

2.0 1.6 1.2 1.0 0.8

How to find the size of the secondary winding wire

To find the proper gauge of the wire 25 0.320 0.45 0.6 of the secondary winding, it must determine the consumption of the 26 0.254 0.40 0.5 amplifier Amp and then see Table AWG . In this case the amplifier consumes 5 amps we got 27 0.202 0.36 0.4 to divide the wattage of your amplifier or transformer between 28 0.160 0.32 0.3 the output voltage (secondary winding). Looking at the 29 0.126 0.28 0.29 table AWG , we see that the 16 gauge wire, supports 5.2 amperes, although in practice, one can use a 30 0.100 0.25 0.22 thinner gauge, for example a 17 (does not fall below a point of the bore, as this may overheat the transformer or not deliver the power required). worth remembering that if you do not know the amps of consumption, simply divide the power between the output volt transformer.

How to find the size of the primary winding wire


To find the size of the primary winding wire, first we have the amperage. This is achieved by dividing the watt amplifier, between the outlet or voltage of the primary winding. Here we have a 115 volt supply to the public network. Amps = Watts RMS / Volt Input Quel it is equal to: Amps = 120W / 115V = 1.04 Amp

120 watts divided by 115 volts equals: 1.04 amps. If we look at our table AWG , the nearest gauge is 23.

As find the area of the transformer core

Now the core section is related to the total power in the following way: Section kernel = PT The core section is equal to the square root of the total power of the transformer. For example, as we saw earlier, got 120 watts of power to the transformer, then the core section is: Section kernel = 120 = 10.95 square inches This means that we can use a core of 3.3 cm wide by 3.3 cm long, corresponding to a core area of 10.95 square centimeters, although not necessarily have to be square. The sheets or plates that come closest, with 3.2 cm long at its center, we would have to put the number of sheets to give us about 3.6 cms wide to achieve that area. Theformwork commercial for this case is 3.2 cm by 4 cm. Measure to define the width of the core by adding plates or sheets of iron

Measure to define the length of the core In the figures, the transformer core appreciated seen above, the core section will be the product of the length in centimeters per centimeter width. This should correspond to the value calculated at least, if older the better, as it gives a certain degree of power.

Calculating the number of turns of copper wire

There is a constant that is the number 42, we will not go into details about the origin of this number, since the idea is not to delve into mathematics. To calculate the number of windings or turns of copper wire, in our example, is divided between 10.95 42 centimeters, which is the core area. # Of turns = 42 / Cm2 10.95 42 divided by 10.95 = 3.8 turns or wire turns per volt . This means, that for the primary winding are 115 volt outlet, by 3.8 equals: 437 turns or turns of copper wire. If in your country the utility voltage is 220V, is multiplied by 3.8 = 220 volts 836 turns in the primary winding. To find the number of secondary winding turns are taken from the 24 volt transformer. This figure is multiplied by 3.8 getting 91 turns or turns of wire.

Connecting two simple transformers

In the case before us difficult to get a transformer with TAP center, a simple option is to connect two simple transformer (no center TAP). shown in the figure as the correct connection is made to convert our simple two transformers in a transformer with TAP center. Besides doubling the amount as iron plates, increases a little power, improving the performance of the two transformers.

Parallel Transformers

Other times it is difficult to achieve high amperage transformers and can not get the materials to do so. To solve this problem you can connect two transformers in parallel and thus double the amperage, voltage and maintain. For example: We need a transformer 18 +18 volts AC, with a current of 12 amps to power the amplifier 300W with TDA7294 . We can connect in parallel two transformers 18 +18 V AC, with a current of 6 amps and so we get the transformer we require for this project .

If desired, you can use a program called transformer calculation , which makes the calculation work for you. For calculations with this program out correctly, you must add two millimeters on each side of the core, since the formwork where the wire is coiled wire occupies space. Alternatively, you can use the official program of our website, which was created by Jaider Martinez, one of our loyal fans. It is a free software to calculate the dimensions, turns and wire gauge, by entering the voltage and amperage.

Some examples of carrying out calculations for transformers


By Federico Michelutti of Argentina. Before the examples we consider the following information:

Table formwork core


Measurement of nucleus area in centimeters. Compare the core area with the closest in the table, use this or the next larger area to which you need and the number of turns per volt, calculate the wire turns of the primary winding and secondary.

CORE 1.6 x 1.9

MAXIMUM POWER 9W

Turns per volt 14

AREA Cm 4.3

2.2 x 2.8 2.5 x 1.8 2.5 x 2.8 2.8 x 1.5 2.8 x 2.5 2.8 x 3.5 2.8 x 5 3.2 x 3.5 3.2 x 4 3.2 x 5 3.8 x 4 3.8 x 5 3.8 x 6 3.8 x 7 3.8 x 8 3.8 x 9 3.8 x 10 3.8 x 11 3.8 x 12 4.4 x 9

37W 20W 49W 17W 49W 96W 196W 125W 163W 256W 231W 361W 519W 707W 924W 1170W 1444W 1747W 2079W 1568W

7 9.3 6 10 6 4.3 3 3.75 3.3 2,625 2.76 2.21 1.85 1.58 1.38 1.22 1.1 1.004 0.921 1.6

6.16 4.5 7 4.2 7 9.8 14 2.11 8.12 16 2.15 19 8.22 6.26 4.30 34.2 38 41.8 45.6 39.6

4.4 x 10 4.4 x 11 4.4 x 12


Core Measure:

1940W 2342W 2787W

0.95 0.867 0.795

44 48.4 52.8

By multiplying ( X ) (width center of the plates) by ( Y ) (background given by the number of plates), we obtain the area in square centimeters of our transformer core. Means in millimeters available that have to ( X ) are: 16, 20, 22, 25, 28, 32, 38, 44, 50, 60, 70, 80, 100. ( Y ) is determined by the number of plates or plates will place one above the other.

Example No. 1:
Input : (primary winding) 220 V Output 1 : (secondary winding) 60V to 4Amp The first thing to calculate is the power of our transformer: In this case: 60V x 4 Amp. = 240 watts Now, if we look at the table above we find the approximate value is: 256W (These are maximum power and must be above to reduce losses).

CORE 3.2 x 5

MAXIMUM POWER 256 W

Turns per volt 2,625

AREA Cm 16

Thus we find the core measure that best suits our needs: X = 3.2 cm for Y = 5 cm

Now, to divide our power amplifier between the input voltage, amperage get the value for the primary winding: 240w / 220v = 1.09 amps. Now look at the table AWG

Caliber 17 23

Circular Mils 2,048 0.509

Diameter mm 1.15 0.57

Amperage 4.1 1.0

You see, we should use for the primary winding, magnet wire 23 gauge and 17 gauge wire for the secondary winding, as this requires 4 amps. To calculate the number of primary winding turns, we must multiply the turns per volt (2.21 in our core formwork table), the amount of input volt transformer (voltage public network): 220 x 2625 = 578 turns for the primary winding. To the secondary winding, the same but with the desired volt output: 60V x 2625 = 158 for the secondary winding turns.

Example No. 2:
Input : (primary winding): 120V Output 1 : (secondary winding): 32 x 32V 3Amp (use TAP Central) The first thing to calculate is the power of our processor, in this case: 32 + 32V x 3 Amp. = 192 Watts Now, if we look at our core formwork table, find the value that is closest to: 196W (maximum powers as they are).

CORE 2.8 x 5

MAXIMUM POWER 196W

Turns per volt 3

AREA Cm 14

Thus we find that core as needed, that is X = 2.8 cm by Y = 5 cm

Now, to divide our power amplifier between the input voltage, amperage get the value for primary winding: 192w / 120v = 1.6 amps. Now look at the table AWG

Caliber 21 18

Circular Mils 810.1 1,624

Diameter mm 0.72 1.2

Amperage 1.6 3.2

You see, we use a 21 gauge for the primary winding, and a 18 gauge for the secondary winding, as this should deliver 3 Amp. To calculate the number of primary winding turns, we must multiply the turns per volt (3 per table formwork core), the amount of volts input (public): 120V x 3 = 360 turns for the primary winding. For the secondary winding, we do the same but with the desired output volts: 64V x 3 = 192 turns. In this case, the return reach 96, should be welded Central TAP cable or wire can wind the double and give only 96 turns, as shown in the video.

Example No. 3:
Input : 220V (primary winding) Output 1 : 24V 3 Amp (secondary winding) Output 2 : 9V to 1.6 Amp (additional secondary winding) The first is to calculate the power transformer must deliver in order to find the appropriate core size.

For this case we take the main secondary power winding, which is: Amp 24V x 3) = 72 watts Then look at the table of core formwork and find the best estimated above, that is: 96W (Note be at least 20% up, thinking of the eddy current losses).

CORE 2.8 x 3.5

MAXIMUM POWER 96W

Turns per volt 4.3

AREA Cm 9.8

Thus we find the kernel as needed: X = 2.8 cm for Y = 3.5cm. Now, to divide our power amplifier between the input voltage, the amperage obtain due the primary winding: 96W / 220v = 0.4 amps. Now look at the table AWG

Caliber 27 18 21

Circular Mils 0.202 1,624 810.1

Diameter mm 0.36 1.2 0.72

Amperage 0.4 3.2 1.6

See, we use a 27 gauge for the primary winding 18 gauge to gauge the secondary winding and to the additional winding 21. To calculate the number of primary winding turns, we must multiply the turns per volt (4.3 per table formwork core) by the amount entered in volts (voltage public network). 220 x 4.3 = 946 turns for the primary winding For the secondary winding must do the same, but with the desired output volts: Vx 24 4.3 = 103 laps. And for additional winding, we have: 9V x 4.3 = 39 laps.

Example No. 4:
Input : 220V (primary winding) Output 1 : 33 to +33 v 3amp (secondary winding) Output 2 : 12v 0.8amp (additional secondary winding) We begin by calculating is the power of our transformer: For this case we take the power of the main secondary winding, which is 33V + 33V x 3 Amp = 198 watts.

Now we look at our core formwork table and find the best estimated above, that is: 231W (Note be at least 20% up, thinking of the eddy current losses).

CORE 3.8 x 4

MAXIMUM POWER 231W

Turns per volt 2.76

AREA Cm 2.15

Thus far we have found the best for our core our core transformer: X = 3.8 cm for Y = 4 cm. Now, to divide our power amplifier between the input voltage, amperage get the value of the primary winding: 231W / 220v = 1.05 amps. Now look at the table AWG

Caliber 22 18 24

Circular Mils 642.4 1,624 0.404

Diameter mm 0.65 1.2 0.51

Amperage 1.2 3.2 0.8

You see, we use a 22 gauge for the primary winding, although you can use 23 gauge, to be very little difference. use for the secondary winding 18 gauge wire, as this needs 3 winding wire 18 Amp and delivers 3.2 amps . And the additional winding 24 gauge wire used, requiring 0.8 Amps. To calculate the number of primary winding turns, we must multiply the turns per volt (2.76 in our core formwork table) by the amount entered volts (voltage public network): 220 x 2.76 = 607.2 turns for the primary winding. For the secondary winding, it does the same, but with the desired output volts: 33 +33 V x 2.76 = 182 laps. In this case, the return reach 91, should be welded Central TAP cable or wire can wind the double and give only 91 turns, as shown in the video. And we have the additional winding: 12Vx 2.76 = 33 laps.

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