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How to design a pulse transformer

_lazor_  44 22470 Cool? (+25)
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TL;DR

  • The text explains how magnetic fields behave in matter, contrasting vacuum fields with diamagnetism and paramagnetism.
  • It attributes diamagnetism to orbital electron motion and paramagnetism to electron spin, showing how molecular dipoles weaken or strengthen an external field.
  • It defines magnetic permeability as u = B/H and notes that diamagnetic media reduce B while paramagnetic media increase it relative to vacuum.
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1. Magnetic field in matter

Prof. Roman Kurdziel „Podstawy elektrotechniki” wydanie II całkowicie zmienione. wrote:
The magnetic field in a vacuum depends only on the electrical circuits that generate it. In material environments, there is also the influence of molecular currents in particles of matter. An electron moving around the nucleus at the angular velocity omega_zero in an orbit with radius r represents an elementary magnetic dipole. Magnetic dipoles are usually arranged chaotically in the matter, so that the body does not show a magnetic state unless it is subjected to an external magnetic field, i.e. generated by external causes, e.g. current in any electrical circuit.
The elementary magnetic dipole placed in the external magnetic field is subject to a mechanical moment, which sets the electron, regardless of the orbital motion, in a precessive motion, similar to the motion of a fob. The axis of the precession is the field strength vector H. As a result, an additional magnetic field is created which slightly weakens the external field. This phenomenon is called diamagnetism.
For the reason given above, all bodies should be diamagnetism. However, in many bodies placed in an external magnetic field, the opposite phenomenon is observed, i.e. a certain strengthening of the external magnetic field. The o phenomenon can be easily explained if it is assumed that the electron, apart from orbital motion, rotates around its axis, called the electron spin. The electron spin is accompanied, regardless of the magnetic moment resulting from the orbital motion, by the spin magnetic moment p_s.
In individual atoms, some electrons spin in one direction, others in the opposite direction, which corresponds to the opposite sense of the spin moment. If the numbers of electrons spinning back and forth are equal, the sum of the spin magnetic moments is zero and the body exhibits diamagnetic properties, resulting from the orbital motion of the electrons. On the other hand, if the number of electrons with a certain direction of spinning prevails, the sum of the spin magnetic moments is different from zero and the atom exhibits a certain resultant spin moment, which in the external magnetic field tends to assume a position consistent with the direction of the field intensity. The spin dipole field and the external magnetic field add up, i.e. the presence of this type of matter increases the magnetic field in relation to the field that a given electric circuit would generate in a vacuum. This phenomenon is called paramagnetism.
The influence of the environment on the magnetic field is thus marked: in diamagnetic environments a decrease, and in paramagnetic environments an increase in the magnetic inductance B in relation to the inductance B_o that a given external field of intensity H would cause in a vacuum. The ratio of the resultant induction B to the intensity of the external field H is called the magnetic permeability of the environment
$$u = \frac{B}{H}$$
(...) At certain values of the ratio of the distance D between atoms to the diameter of the atom d, namely when 1.5

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_lazor_
_lazor_ wrote 3795 posts with rating 1130 , helped 259 times. Live in city Wrocław. Been with us since 2016 year.

Comments

SylwekK 14 Aug 2019 22:45

I wound up my first network hit (and the next few) in primary school. My father subscribed to a young technician in which all necessary calculations were described. These transformers are still working... [Read more]

And! 14 Aug 2019 23:08

In general, the topic is beyond me, so after reading I did not speak, but since the topic of network transformers was raised, then I will ask for one detail, maybe I can find the answer to such a question:... [Read more]

_lazor_ 14 Aug 2019 23:14

I'm not an expert on network transformers, but they probably weld to minimize costs. After all, everything must fit tightly so that it does not buzz too much and the use of screws and flat bars would... [Read more]

And! 15 Aug 2019 01:08

It can really be an optimization of production costs, but whether such welding does not increase the loss in the core and more specifically eddy current. [Read more]

ArturAVS 15 Aug 2019 07:07

It increases, it also causes a large no-load current. Note, however, that such luck works casual. [Read more]

Anonymous 15 Aug 2019 09:12

Me too but once it was normal because buying a transformer was not so easy. There is a simple way not to count complicated designs. When the mains transformer is called, count the turns when unwinding... [Read more]

ArturAVS 15 Aug 2019 09:20

Yeah, and who will want to count those unwound rolls? Simple and proven pattern: As I remember, this pattern has two characters differing in number 45 vs 44, one for continuous work and the other... [Read more]

_lazor_ 15 Aug 2019 09:20

However, times are changing and network transformers are less and less used. Instead they are switched-mode power supplies, which are highly optimized and often you can forget about rewinding. However,... [Read more]

SylwekK 15 Aug 2019 09:32

I also used this obvious method. My father rewound the engines, I had access to virtually any size of DNE, and the winder that counted the unwound turns helped me count the turns. :) Unfortunately, it... [Read more]

ArturAVS 15 Aug 2019 09:35

By all means I meant mains transformers, where we have sinusoidal voltage. [Read more]

Anonymous 15 Aug 2019 09:44

I think he used to? You can scroll it on the stick .. Once on the net I found a spreadsheet in exel to calculate goes. If I find it I will post on the forum. [Read more]

Renegat_pol 15 Aug 2019 09:49

The reality of the 1980s. There was nothing to do with the carcass. In the factory where I had apprenticeships, the bobbins were made of ... fiberboard. [Read more]

Anonymous 15 Aug 2019 21:51

With microwave welding from a microwave it seems a simple matter. It is about magnetostriction and acoustic experience that would accompany this size of a fully loaded transformer. Welding the sheet metal... [Read more]

rysieklew 15 Aug 2019 22:28

Hello, I used to use the article from the Young Technician for calculations, then the Excel spreadsheet. Now it is the low and medium power power supplies that are replaced by switching power supplies.... [Read more]

Mark II 15 Aug 2019 22:32

Modern low power industrial on classic EI shapes are also welded. I suppose that in this case the reduction of production costs is of particular importance. [Read more]

^ToM^ 16 Aug 2019 09:17

No, the higher value was for small transformers and the smaller for larger ones made of better transformer sheet. The counter ranged from 43 to even 48. It all depends on which core and transformer the... [Read more]

_lazor_ 16 Aug 2019 09:28

All in all, you don't need to include insulation between packet sheets in your formulas and add a column fill factor? [Read more]

OldSkull 16 Aug 2019 09:49

It is a pity that the assumption in the calculations is the lack of a gap. In practice, the gap is very important, because although it reduces inductance, it protects against saturation of the core. Unfortunately,... [Read more]

_lazor_ 16 Aug 2019 10:02

Generally, the slit causes many unwanted effects like: - increasing the number of turns - the stream in the crevice likes to run sideways, which can cause problems with EMI - energy accumulation... [Read more]

FAQ

TL;DR: 45 turns per volt at 50 Hz is a classic rule, and “the gap increases the number of turns” [Elektroda, ArturAVS, #18116092; lazor, #18117941].

Why it matters: Correct turns, gaps and wire size mean cooler, quieter, safer transformers.

Quick Facts

• Turns-per-volt for 50 Hz silicon-steel cores: 43–48 t/V depending on grade [Elektroda, ^ToM^, post #18117870] • Recommended copper current density: 2–3 A /mm² for hobby builds [Schmidt-Walter]. • Typical ferrite saturation flux density: 0.30–0.45 T at 25 °C 3C90 Spec. • Welded microwave oven transformer (MOT) no-load current: “very high” (>1 A) [Elektroda, ArturAVS, post #18115998] • Air gap cuts inductance roughly inversely with gap length TI SLUP126.

Why are microwave oven transformer (MOT) cores spot-welded?

Spot welding locks the EI stack quickly and cheaply. Manufacturers save screws and varnish steps [Elektroda, lazor, post #18115794]

How do I size winding wire?

  1. Estimate RMS current.
  2. Allow 2–3 A /mm² for ventilated hobby units [Schmidt-Walter].
  3. Check copper loss: P = I²R; keep total loss <30 % of core loss TI SLUP126. High-temperature or potted designs may need 1 A /mm² [Elektroda, lazor, post #19106231]

Is 3 A /mm² safe for a 20 W SMPS?

Yes, light SMPS under 30 W often run 3 A /mm² because the small bobbin dissipates heat easily [Elektroda, chlebok, post #19275104] Ensure winding temperature stays below 105 °C insulation class.

Must I include fill factor when counting turns?

Include it if laminations are insulated. Effective core area is about 90–95 % of measured due to paper or oxide gaps [Elektroda, lazor, post #18117885] Neglecting it overestimates flux margin.

How does an air gap change a pulse transformer?

A gap lowers inductance, raises magnetizing current, widens energy storage and forces more turns [Elektroda, lazor, post #18117941] Designers add gaps for flyback but avoid them in resonant SR LCC units.

What is the proximity effect and when is it relevant?

Adjacent conductors push current to outer strands, effectively shrinking copper area. Above 100 kHz or for foil windings, loss can exceed skin effect loss by 30 % Page: RL Core Losses. OldSkull flagged this for SMPS faces [Elektroda, OldSkull, post #18117921]

Quick way to redesign a mains transformer?

Count removed secondary turns, divide by measured volts to get t/V, rewind new secondaries with same t/V and right wire gauge [Elektroda, o_Tadeusz, post #18116084]

3-step how-to: measure turns-per-volt

  1. Apply 1 V AC to a known winding.
  2. Measure induced volts on another winding.
  3. Divide turns ratio by voltage ratio to get t/V.

What happens if you exceed core saturation?

Magnetizing current spikes, cores overheat, and fuses may blow. MOTs can draw several amperes unloaded because they run near saturation by design [Elektroda, ArturAVS, post #18115998]

How does an LCC resonant converter use secondary winding capacitance?

The secondary’s inter-turn capacitance acts as the series resonant capacitor. In an LCC running 30 V→15 kV, this raises secondary voltage without extra parts [Elektroda, lazor, post #18396474]

Expert tip: why avoid 2–3 turn primaries?

Few primary turns magnify parameter spread; a small core or air gap shift can halve inductance. “Repeatability of conductors is of great importance” [Elektroda, OldSkull, post #18118041]
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