Usually, I would ignore such videos, but this series is (almost) perfectly descriptive. All of the information and calculations that are needed, are included. The only issue that I could find is that sometimes video is spliced and it appears that some info or calculation is missing.
Well, I think that for practical purposes, your calculations are more than enough, so, Why should we complicate ourselves trying exact ones? Thank you very much again.
Transformer formula: TPV=10^8/4.44*Bmax*f*Ac Descriptions: TPV= Turn Per Volt 10^8 and 4.44 are constants Bmax= maximum number of magnetic lines of force easily passable through one square inch area (which is 65000 lines per square inch for small transformers i.e. below 36 watts and 60000 lines per square inch for larger transformers i.e. above 36 watts, this is also called flux density f= frequency in Hz Ac= Area of core in square inches why in square inches? because we are counting flux density through square inches, we can convert it into square centimeters (or any other unit) if we wish. ------------------- An other formula to find Area of core, provided you already have wattage in your mind: Square Root of watt divided by 5.58 i.e. √watt/5.58 in other words (watt)^0.5/5.58 Note that 5.5 is a constant.
perfect sir. 4.44 is constant for ac signal, but for square wave pulsed DC it is 4. Bmax will change according to core material type and frequency, for example for a P material ferrite core switching at 20KHz will allow 1600 guases and at 100 KHz it will allow 900 guases
Thank you very much, this is amazing. But what if I use an EI core, what would be the Kt factor? Since here your example is using an EE one. Thanks in advance.
Based on the chart 50Khz would be closer to 1600 gauss. Calculation comes to 1416watt and the difference of 1100watt could be attributed to the bobbin.
Excellent tutorial thanks you. Also my question is how do I calculate the value of the common mode choke, X-capacitors, Y-caoacitors for effective emi filtering
Thanks Haseeb Sab for detailed video, I am Alok from India, I have made a 66.6 Volts & 15 Amps = 1000 Watt (Max) smps transformer according to your calculation, I have used EE 55/28/21 core with 50 Khz frequency, the output is as expected, the only issue is that the transformer is getting a littel too hot, can you please advise on this please
In the real world things are bit different. It is a fact that there are many different types of power ferrites. And also the permitted flux densities etc. and therefore transmitted power are also different. For example, a much more realistic calculation (which I use in real life) gives completely different numbers for the same E55/28/21 core. For example, it is more realistic that in the case of Ferroxcube 3C85 and 3C96 ferrites, where same E55 core size gives a difference of about 1000W, and this already at a frequency as only as 50kHz, as the indicator of different ferrite brands of other manufacturers is also different. By the way, the same Ferroxcube E55 3C96 core is suitable for about 3.5kW conversion at 50kHz and !without forced cooling!, and here * these calculations have not been taken to the last limit *, but there is still some margin left. It is not a problem to take 3-4kW of power from E55 core at frequencies below 100kHz, and at 100kHz the 3C96 with the same 3C96 is good for about 5kW conversion. PQ cores are much better, the PQ4040 size can easily use 3+kW of power as a transformer for example in a half-bridge topology. These facts are easy to check and proven - even by looking at commercially produced inverter welding machines. 1100W from E55 core? It's a bit waste of good, big cores if an E42 or ETD39 core does the same job. By the way, there are still losses when using thick single wire for windings, etc., just like in commercial PC power supply units - I did an experiment and new power supply unit with a power of barely 300W with its ETD34 transformer, which was produced with windings with thick solid wires, gave almost 470W after rewinding with litz wire and only because of this modification - so the use of litz wire is very important if the powers/Fq`s are higher, even 40+kHz gives better results in terms of litz efficiency (at least in my favorite, half-bridge circuits)
In what video is the Current density handled in detail ? So the unit for 500 or 750 is mills²/A ? Is it the RMS current or the Peak current ? Thanks for this very informative video !
Hello brother, how are you, can you put a video explaining the method of calculating Bmax to saturate the ferrite using devices, such as an oscilloscope ...
Please confirm how you define switching frequency for push /pull .Is it the chip switching frequency or the transformer switching frequency? The transformer switching frequency is 50% of the control chip switching frequency for push/pull .
For one E it is 1. For 2 E's it would be 2, but due to area losses in winding en used space by the plastic bobin holder, 1.5 is used (1.4 if badly winding)
Poloneise Czy pomógłbyś mi policzyć transformator do fullbridge? Mogę podać jaki posiadam rdzeń, częstotliwość, napięcie zasilania fullbridge. Dziękuję
sir i always face a problem in air gap. currently im making a uc3843 base smps but im still confuse about the air gap☹☹☹. can you please tell me about it 🥺🥺🥺😢😢😢
this is so strange that in formula of Po are being used Gauses, cm, and current dencity in mils..... In SI system B is measured in (T), distances in (m), and current density in A/sq.m...
Mujhe static stapliser banana hai circuit se koi aisa ic bataye jisme ac pulse in karke same pulse output de mosfet drive karne ke liye or ek control pin ho jisse uska peak voltage control Kar sake Jo bhi ic milta hai usme with control hota hai hum banaye the 3525 ic se to usme line ka pulse in karte hai sync pin me so usse drive voltage shareware nikal jata hai lekin Starting 0 digree se 180 digre 180 se 360 degree lane se compare ho jata hai starting and last wave line se mix karma tha wo to ho jata hai par sure wave rehta hai or voltage control karne par with control hota hai jo humko peak se voltage control chahiye with se voltage to stable ho jata hai par isse smps ko nuksan hoga or sqare wave me fan me aawaj aa jata hai iska solution bataye please ye topic bilkul alag hai ic mile to thik hai nahi to program se solution hoga kya humko manufacture karna hai
oh No dear brother. aisi baat nhi he. me just office me busy rehney ki wajah se zayaada videos share nhi kr sakta. me ne note kia hua he. me jald is ka complete procedure share karoon ga. me tochaahta hoon k her question ko reply karoon. abhi 1000+ videos ki request he. whatsapp per itney message hein, k aik side se start kia hua he reply karna. abhi 5 March 2021 k messages ko reply kar rahaa hoon.
hello there! i have an unknown toroid core with OD36mm ID23mm and height 15mm. it is gray color and i think it iron powder material not MnZn. 8 turns inductance is about 750uH. I've been driving it in push-pull and I've got max 5 watts before the voltage collapses at 50 and 60khz. any help on why is that and how can i get more power? Np= 4+4, Ns= 8+8.
![[430] How To Calculate Ferrite Core Maximum Power Handling to Design High Frequency Transformer](/img/logo.svg){kind=logo}
