Design of transformer:

the transformer isolates the source and load. Here transformer isolates the source and buck
converter. As we have power rating of transformer, we will have to design number of turn on
primary and secondary and area product of transformer for given flux density.

The input voltage of transformer is same as capacitor (C1) voltage which is equal to 86V.
The selected turns ratio of transformer is 2.5, so the maximum output voltage is 215V.
Maximum primary current of transformer is 5A and the maximum current of secondary is
2A.

The area product of transformer is

Area product

Ap=((Po*(1+Po/Pin))/((sqrt2) *Kw*Kf*J*fs*Bm).

For high frequency transformers we use

The maximum flux density is taken as Bm=0.2T and the winding factor Kw =0.4, converter
efficiency is =75%, the current density(J) of the conductor is taken as J=3A/ mm2.

The form factor of current waveform in transformer is Kf=1.49.

By substituting all above values in the equation, we will get area product Ap=65249.98mm4.

I am selecting EE core

The near EE core is EE 65/32/27

The area of cross section Ac=535mm2.

The window area Aw=435mm2.

Number of turns on primary N1= (Vin)/(2*Ac*Bm*fs)

N1=40 turns, N2= 100 turns

The current ripple of transformer primary is 5A , the inductance of primary is 1.4mH.

The secondary turns N2= 100 inductance of secondary is 8.75mH.

Wire gauge as we took J=3A/ mm 2, the gauge of primary wire of current 5A is 17, and the
secondary wire gauge is 20.
Designing of inductor:

The value I got after designing of filter inductor is L=2.57mH, the peak current flowing
through the inductor is 10A.

To design an inductor first we have to find the area product of the inductor

2E
Ap=
KwJBm

Where E is the maximum energy that is stored in the inductor during operation. E= Li 2/2

E=128.5mJ

Kw=0.6 for filter inductors, J=3A/mm2, maximum flux density for inductor is Bm=0.25T

By substituting the above values in area product Ap=36666.7mm4

For the above value of area product, the core selected is EE 42/21/15.

Area product for that core is Ap=46590mm4

Number of turns N=(LIp/Ac*Bm) where y is permeance of the core

From EE 42/21/15 the Ac=175mm2

N=125 turns