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Derivation of Formula For Calculation of Turns Per Volts of Transformer Design
Derivation of Formula For Calculation of Turns Per Volts of Transformer Design
Design
For designing a transformer, we need certain number of turns on each side for a
specific rating transformer. Voltages on each side have direct relation with number
of turns. So, we are interested in finding voltage per turn and for designing, turns
per voltage. This is obtained from basic voltage equation of transformer:
This equation is derived from basic equations. Here, we are going to derive this.
As we know that emf induced is given by rate of change of flux:
RMS value is linked with with peak value i.e. . So, putting this we get:
Fo
r Maximum flux linkage
This is total emf induced. But we are interested in voltage per turn. So, dividing
both sides by total number of turns (N).
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)
Calculations:
1. Core Calculations:
Calculate area of core (central limb) by using following formula:
As, we are going to design a practical transformer so we must consider the core
available in market. The standard Bobbins available in market practically is 1x1,
1.25x1.5, 1.5x1.5 and so on. We took nearest core area available to our
calculation. We took bobbin of 2.25 inch2 (1.5x1.5) 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=
Number of Turns:
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)
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,
Secondary Wire =15 AWG
Number of Turns:
Number of secondary turns = turns per volts x secondary volts
N2 = 2.6 x 12 = 32 turns (approx.)
Primary side:
So,
As,
area of primary conductor = 0.1 mm2
= (0.1 x 10 ^ -6) m2
Volume of copper wire = area x length
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So,
L2 = 0.1778 x 32
L2 = 6 m (approx.)
As,
area of primary conductor = 1.83 mm2 = (1.83 x 10 ^ -6) m2
Table 1:
Calculation for primary side
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Table
2: Design Summary for Secondary of transformer design
Procedure and Instructions:
It is easiest to wind a transformer and following the easiest steps and instructions
written below:
1. Take the bobbin and if you want to use winding machine, prepare it on the machine
with suitable placement. Otherwise just check if it is cleans and clear.
2. Place insulation paper to its perimeter just to make symmetric. Or else no need of
insulation paper at first layer.
2. Primary Windings:
1. Take the copper wire of primary side for winding.
2. Leaving a little portion 6-8 inches, start the winding around the bobbin perimeter. (As
shown in figure 2)
3. Make turns of those wires by rotating the bobbin on winding machine. If you are
doing it by hand you have to do some work but it is not such problem in small
transformer.
4. Each turn must be tight and very adjacent to previous turn leaving approximate no
space between them. Neither has it gone overlap on previous. (figure 3)
Figure 3: tighten the
winding
5. When you are done with the first layer, i.e. the complete bobbin space is filled, now
move towards second layer.
6. Write number of turns and number of layer on insulation paper after each layer just
as milestone.
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3. Secondary Windings:
1. When you done with primary, place insulation paper and start winding secondary
side wire over it. You can start winding secondary from either starting or ending side of
primary (figure 5 point 1).
2. Do the winding same as primary and make layers if necessary. Now you are done
with the winding. At this time it is just two coils wound on one another. (figure 5)
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3. In Figure 6 the Complete winding of Primary and Secondary. at tag 1 the two sides of
primary side and tag 2 shows secondary side of transformer
4. At this time it is just two coils with out core. for complete transformer we have to
place the iron core.
4. Iron Core:
1. Its time to place core to the transformer. Take two E of laminated iron strips and
insert inside the bobbin.(figure 7) Take another two E and place inside but from
opposite side as previous. (figure 8)
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