TRANSFORMER DESIGN

The transformer in the converter is designed by using some parameters, such as : Permeability of free space o = 4.10-7 (H/m) Wire resistivity =1.74.10-6 (-cm) k N j Total rms winding currents I tot = Ij (A) j =1 N i Peak magnetizing current IM,max = I +I (A) Desired turns ratio N2/N1; N3/N1 etc Magnetizing inductance Lm (H) Winding Resistance R () Winding fill factor Ku = 0.5 Maximum flux density Bmax = 0.25 (Tesla) Cooper loss Pcu = 0.75W-1.5W The core dimensions are expressed in : Core cross-sectional area Ac Core window area Aw Mean length per turn MLT (cm2) (cm2) (cm)

The procedure of transformer design is used the following step. These procedure is usually employed for flyback or forward transformer. A. Determine core size The core size is determined by the Core Geometrical Constant ( Kg ) 2 2 .L2 .I tot .I M ,max 8 M Kg 10 (cm5) where Pcu = 1.5W 0.75W , 2 Bmax .Pcu .K u Chose the core that has Kg is bigger than the accounting value.

B. Determine air gap length It can be calculated by following formula : .LM .I 2 l g = o 2 M , max 10 4 (m) Bmax . Ac C. Determine number of winding 1 turns It can be calculated by following formula L .I N1 = M M , max 10 4 Bmax . Ac D. Determine number of secondary turns Use the desired turns ratios : N N 2 = 2 N1 N 1

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E. Evaluate fraction of window area allocated to each winding N .I 1 = 1 1 N 1 .I tot

N 2 .I 2 N 2 .I tot F. Determine wire size It can be calculated by following formula .K W Aw1 1 u . A n (cm2) 2 .K u .W A Aw 2 n

2 =

Example : Flyback converter operates in the continuous conduction mode with an input voltage of 100 V and produces an full load output of 15 V at 5 A. The switching frequency is 100 kHz, duty cycle is 0.4 and the turns ratio is N2/N1=0.225, Pcu=1.5W, Ku=0.3 and Bmax=0.25T. Design transformer for this converter.

Solution : The dc component of the magnetizing current can be found to be N2 Vo = 1.875 A I Lm = (1 D) R N 1 The minimum magnetizing inductance

(1 D) 2 R N 1 Lm (min) = N = 106.67uH 2f 2 The magnetizing inductance ( in CCM ) should be Lm = 1.25 xLm,min = 134uH

The maximum value of the magnetizing current is i V DT = 3.37 A i Lm ,max = i Lm + Lm = i Lm + s 2 2 Lm

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The rms value of the primary winding current is

i 1 = i Lm 1 (i / 2) = 1.31A D 1 + Lm 3 i Lm
2

The rms value of the secondary winding current is

N 1 ( i / 2 ) = 5.82 A i 2 = 1 iLm D 1 + Lm N2 3 iLm The total rms winding current is equal to N itot = i1 + 2 i2 = 2.62 A N1 We now determine the necessary core size. 2 2 .L2 .I tot .I M ,max 8 M 10 Kg 2 Bmax .Pcu .K u

(1.724.10 6 )(134.10 6 ) 2 (2.62) 2 (3.37) 2 8 10 = 0.0086cm 5 (0.25) 2 (1.5)(0.3) The core that is chosen for above value is PQ 20/16 (Kg=0.0224cm5) and dimension of this core are Ac =0.62 cm2; WA=0.256 cm2; The air gap length (lg) can be calculated 2 o .LM .I M ,max 4 lg = 10 2 Bmax . Ac Kg

lg =

(4 .10 7 )(134.10 6 )(3.37) 2 4 10 = 0.493mm (0.25) 2 .0.62

The number of winding 1 turns is LM .I M ,max 4 N1 = 10 Bmax . Ac (134.10 6 )(3.37) 4 10 (0.25)(0.62) N 1 = 29 To obtain the desired turns ratio, N2 should be chosen as follows N N 2 = 2 N 1 = (0.225)(29) N1 N1 =

N 2 = 6.5 = 7 The fractions of window area allocated to windings 1 and 2 are i 1.31 1 = 1 = = 0.5 itot 2.62

2 =

N 2 i2 (7)(5.82) = = 0.54 N 1itot (29)(2.62)

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The wire gauges should therefore be .K W (05)(0.3)(0.256) Aw1 1 u . A = = 0.00132cm 2 N1 29 use#27AWG (d=0.4mm)
Aw 2 (0.54)(0.3)(0.256) = 0.006cm 2 N2 7 use#20AWG (d=0.8-0.9mm) =

2 .K u .W A

Edited by ZEN/2005