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.
What does the 45 turns-per-volt rule mean?
Why are microwave oven transformer (MOT) cores spot-welded?
Does welding increase core losses?
How do I size winding wire?
- Estimate RMS current.
- Allow 2–3 A /mm² for ventilated hobby units [Schmidt-Walter].
- 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?
3-step how-to: measure turns-per-volt
- Apply 1 V AC to a known winding.
- Measure induced volts on another winding.
- Divide turns ratio by voltage ratio to get t/V.
What happens if you exceed core saturation?
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]
Generated by the language model.
Comments
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]
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]
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]
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]
It increases, it also causes a large no-load current. Note, however, that such luck works casual. [Read more]
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]
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]
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]
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]
By all means I meant mains transformers, where we have sinusoidal voltage. [Read more]
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]
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]
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]
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]
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]
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]
All in all, you don't need to include insulation between packet sheets in your formulas and add a column fill factor? [Read more]
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]
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]