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Tranformer Making Procedure PDF
Tranformer Making Procedure PDF
(manual procedure)
By
Kalpesh
Introduction:
This document illustrates how to wind the transformer used to obtain house-
keeping power supply voltages on typical small circuits. Such transformers have
been used on PCBs .
Material required:
The following materials are required to wind this transformer:
1) EE 25x7 Ferrite core
2) Bobbin (horizontal : implying the core lies horizontally) for this core
3) Wire: 35 SWG (Standard Wire Gauge) enameled wire, or dual coated wire
4) Cello-tape (10-12mm width) or Taco Tape
5) PVC insulating tape for SMPS design (5mm wide roll)
6) Teflon tape – used by plumbers – available at any hardware store
7) Fevikwik or any equivalent cyano-acrilite adhesive
8) Glue stick pieces – for securing the winding in certain steps
9) Tools: Thin triangular file, knife, soldering iron/solder wire.
Preliminaries:
The following diagram illustrates the winding details of the transformer. The
most important thing to follow is the dot-convention. The diagram along-side
shows the winding details for our house-keeping transformer. The view is
from the top. That is as
you see it from top of the
PCB. The pins are on the
other side of this view. All
the three primary side
windings (mains, 230V
side) are connected to
pins on one side of the
bobbin, and all the low
voltage secondary side
windings are on the other
side. This provides for an
extra degree of safety to
isolate the primary and
secondary side of the
transformer windings with respect to PCB connections and tracks.
Physically, this means that both windings, say starting from the ‘dot’ end, will
have the same sense of turning around the core (say clockwise for both or
anticlockwise for both). Both turn the same way, and this is the most
important thing to remember in dot conventions. If they turn the opposite way,
then the phase difference will be 180 degrees (i.e. of opposite polarity).
To avoid confusion during winding, it is best to mark small dots on the plastic
bobbin using the hot tip of your soldering iron. It is also good to mark pin 1
with a ‘1’ mark, so that all the other pins may be located unambiguously
(follow the same convention used in IC pin numbering). In the images below
the dots are marked. I did not get to mark the ‘1’ at this stage, but did it at the
end. It is better to mark at the start itself.
Construction:
The following procedure illustrates the step-by-step construction of this
transformer. Most of the steps are indicated with images, so that there is no
confusion about the steps.
Step1: Wind NP
Start NP, the primary side
winding. We start by
removing insulation from the
end of the enameled wire
(35 SWG), say 15mm and
then tinning that end. Then
solder it to pin8 of the
bobbin.
Dimensionally the
bobbin can take up to
56-57 turns. Our target
is to put 55 turns on
this first layer.
Once the first layer is done, continue to wind on layer two, i.e. above layer 1,
until the winding reaches the starting end once again. Typically, if the winding
is done with care
(remember we are
doing this winding
manually), one
should be able to
accommodate 55
turns on each of the
layers. The two layers
together will therefore
provide the full 110
turns which are
required for NP.
This wire will continue to make the next winding to pin10. But first the surface of
this winding must be insulated with tapes. Notice a few small errors during the
winding led to a little anomaly close to the center of the winding.
The Teflon tape being soft, makes a nice insulating layer, just above NP. The
surface becomes smooth when the softer and fragile Teflon tape insulation is
enhanced with cello-tape for mechanical strength. The other windings are may
be put on top of this insulating layer. Now that NP is secured well in the bobbin,
one can remove insulation from the enameled wire and solder it to pin9 (dot) of
the bobbin.
It is important to make
sure that the PVC tape
insulation is also
provided between the
return wire (going to
pin10 and the already
wound 5 turns of wires of NP2, starting from pin9. This process will be true for all
such windings.
Now all three primary side windings are done (pins 6-10). As the photograph
shows, these windings are all well insulated from any other winding that may be
created for the primary side (pins 1-5). In this application, the secondary (low
voltage) windings have very few turns, and they could all get accommodated on
the remaining half of the layer3 space. These secondary windings must also be
well insulated with respect to each other.