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Chapter - 15 - Transformer Design
Chapter - 15 - Transformer Design
Chapter - 15 - Transformer Design
Core loss
P fe = K fe(∆B) β A c l m
v1(t)
Flux density B(t) is related to the
applied winding voltage according area λ1
to Faraday’s Law. Denote the volt-
seconds applied to the primary
winding during the positive portion
of v1(t) as 1: t1 t2 t
t2
λ1 = v1(t)dt
t1
ρ λ 21 I 2tot (MLT ) 1 2
Pcu =
4K u W A A 2c ∆B
Co
Ptot
fe
ss P
ppe
o
r lo
re l
ss P c
Co
Ptot = Pfe + Pcu
u
P fe = K fe(∆B) β A c l m
Optimum ∆B ∆B
ρ λ 21 I 2tot (MLT ) 1 2
Pcu =
4K u W A A 2c ∆B
Given that
Ptot = Pfe + Pcu
Then, at the B that minimizes Ptot, we can write
dPtot dP fe dPcu
= + =0
d(∆B) d(∆B) d(∆B)
Note: optimum does not necessarily occur where Pfe = Pcu. Rather, it
occurs where
dP fe dPcu
=–
d(∆B) d(∆B)
dP fe dPcu
Now, substitute into =– and solve for B:
d(∆B) d(∆B)
1
β+2 Optimum B for a
ρλ 21 I 2tot (MLT ) 1 given core and
∆B =
2K u W A A c l m βK fe
3
application
Substitute optimum B into expressions for Pcu and Pfe. The total loss is:
β
β 2
β+2
2 ρλ 21 I 2tot (MLT ) β –
β+2 β β+2
Ptot = A c l m K fe β+2 +
4K u W A A 2c 2 2
Rearrange as follows:
β+2
–
β β 2/β
WA Ac
2(β – 1)/β
β –
β+2 β
2
β+2 ρλ 21 I 2tot K fe
+ =
(MLT )l m2/β 2 2 β + 2 /β
4K u Ptot
2/β
ρλ 21 I 2tot K fe
K gfe ≥ 10 8
β + 2 /β
4K u Ptot
1
β+2
ρλ 21 I 2tot (MLT )
8 1
∆B = 10
2K u W A A 3c l m βK fe
At this point, one should check whether the saturation flux density is
exceeded. If the core operates with a flux dc bias Bdc, then B + Bdc
should be less than the saturation flux density Bsat.
If the core will saturate, then there are two choices:
• Specify B using the Kg method of Chapter 14, or
• Choose a core material having greater core loss, then repeat
steps 1 and 2
Primary turns:
λ1
n1 = 10 4
2∆BA c
n 1I 1 α 1K uWA
α1 = A w1 ≤
n 1I tot n1
n 2I 2 α 2K uWA
α2 = A w2 ≤
n 1I tot n2
n kI k
αk =
n 1I tot
Predicted magnetizing n1 : n2
inductance, referred to primary:
i1(t) iM (t) i2(t)
µn 21 A c
LM =
lm LM
Peak magnetizing current:
λ1 R1 R2
i M, pk =
2L M
Predicted winding resistances: ik(t)
ρn 1(MLT)
R1 =
A w1
ρn (MLT)
R2 = 2 : nk
A w2 Rk
1/4.6
= 0.0858 Tesla
–6
(62.5⋅10 )
n 1 = 10 4
2(0.0858)(0.635)
= 5.74 turns
n1
n 2 = n = 1.15 turns
In practice, we might select
n1 = 5 and n2 = 1
This would lead to a slightly higher flux density and slightly higher
loss.
Primary
5 turns #16 AWG
Secondary
1 turn #9 AWG
4226
3622 0.1
0.08
Pot core size
Bmax , Tesla
2616 2616
2213 2213
0.06
1811 1811
0.04
0.02
0
25 kHz 50 kHz 100 kHz 200 kHz 250 kHz 400 kHz 500 kHz 1000 kHz
Switching frequency
Q1 Q3 T1 I5V
D1 D3
n1 : : n2 i2a(t) 100 A
+
+ D5
Vg + i1(t) v1(t)
– 5V
160 V
– D6 i2b(t) –
: n2 I15V
D2 D4
Q2 Q4 : n3 i3a(t) 15 A
+
D7
Switching frequency 150 kHz
15 V
Transformer frequency 75 kHz D8 i2b(t) –
Turns ratio 110:5:15 : n3
v1(t) Area λ1
T1 Vg
D3 = Vg DTs
n1 : : n2 i2a(t)
0 0
+ D5
– Vg
i1(t) v (t)
1
i1(t) n2 n
I 5V + 3 I 15V
– n1 n1
D6 i2b(t)
0
: n2
D4
n2 n
: n3 i3a(t) – I 5V + 3 I 15V
n1 n1
D7 i2a(t)
I5V
0.5I5V
0
i3a(t) I15V
D8 i2b(t) 0.5I15V
: n3 0
0 DTs Ts Ts+DTs 2Ts t
v1(t) Area λ1
Vg = Vg DTs
0 0
– Vg
i1(t) n2 n
I 5V + 3 I 15V
n1 n1
n2 n
– I 5V + 3 I 15V
n1 n1
n2 n3
I 1 = n I 5V + n I 15V D = 5.7 A
1 1
i2a(t) I5V
0.5I5V
0
i3a(t)
I15V
0.5I15V
0
0 DTs Ts Ts+DTs 2Ts t
I 2 = 12 I 5V 1 + D = 66.1 A
I 3 = 12 I 15V 1 + D = 9.9 A
nj n2 n3
I tot = Σ
all 5 n1 I j = I 1 + 2 n1 I 2 + 2 n1 I 3
windings
From Appendix D
1
2 2 β+2
Eq. (15.20): 8 ρλ 1I tot (MLT) 1
Bmax = 10
2K u WAA 3c l m βK fe
Plug in values:
1/4.6
= 0.23 Tesla
I1 α 1K uWA (0.396)(0.25)(1.78)
α1 = = 5.7 = 0.396 A w1 = =
(22)
= 8.0⋅10 – 3 cm 2
I tot 14.4 n1
⇒ AWG #19
n 2I 2 αKW (0.209)(0.25)(1.78)
α2 = = 5 66.1 = 0.209 A w2 = 2 u A =
(1)
= 93.0⋅10 – 3 cm 2
n 1I tot 110 14.4 n2
⇒ AWG #8
n 3I 3 αKW (0.094)(0.25)(1.78)
α3 = = 15 9.9 = 0.094 A w3 = 3 u A =
(3)
= 13.9⋅10 – 3 cm 2
n 1I tot 110 14.4 n3
⇒ AWG #16
Window area WA
i(t) + Core mean length Core
per turn (MLT ) Core area
Ac
v(t) L
n
turns Air gap
lg
–
Wire resistivity ρ
v(t)
Area λ Fill factor Ku
t1 t2 t
Relationship between
applied volt-seconds and Must select core that satisfies
peak ac flux density:
2/β
ρλ 2I 2K fe
∆B = λ K gfe ≥
2nA c 2K u Ptot
β + 2 /β