Sir you have given each and every minute aspect of design of SMPS ferrite transformer. I have seen many tutorials in this regard but this is the most exhaustive explanation ever I seen.Thank you very much.
Thank you very much Mr. Silvio de Leonardo, thatś a huge help. I have have some dificulties with the formulas but you made it quite easy to understand. Keep doing the good job ...
OLÁ SILVIO !!! É MUITO FÁCIL DE ENTENDER SUAS EXPLICAÇÕES , POIS TUDO É ESCLARECIDO COM RICOS DETALHES , SEM NADA OMITIR .. MEUS PARABÉNS , E CONTINUE SEMPRE ASSIM !!!
Thank you very much Silvio De Leonardo. This is the best video on youtbe. so very good explanation. and English is very very good. well done. Thank you. :)
Hi There. I was some busy with the smps, I have decided to use resonant version, one with current feedback so I have fast respons and still stability. Did go to 10 amps 65 x 65 who is more then enough, the smsps can do easely the music peaks who live short, and I do never play so loud, ears will be give up earlyer then the suppy. For the tubes a 100 watt (overkill) LCC resonant can do, (also for audio better) these can run very nicely also without a load, burst mode for llc is not what I want, the ripple get bad and I need clean amp because it is high end class hybrid. The question now, LCC resonance do need a transformer calculation, and in all papers she just talk about N this is coupled with tank calculations, never I see how high induction will be only AC who is the load max and min. I presume the smps transformer needs to have these reactante with max and min load valeu? I do not now if you did resonance stuff, for LLC I do have tools and can calculate for LCC not because it is a older system, but it is used for led,s because of the nice respons for that. regards
1. Formula Shown at Video time 10:15 will also work for a uncut Ring/Toroidal core? 2. What will be the rough B max value we should consider for uncut Ring Core?
B max will change according to frequency used 2000 guass at 20Khz and 1200 guass at 100khz. As for the ring core you can calculate the core area and plug it in the formula. Make sure that it is not a powdered iron core as it is not suitable. They act as core with air gap.
Here is the link for the Copper wire table diyaudioprojects.com/Technical/American-Wire-Gauge/ One can also pause the video at 32:17 and copy it from there. Please note that the table is not downloadable however a screen shot can be taken and then printed.
Thank you for this really good video on transformer winding calculations. I was just wondering whether the auxiliary coil layer would be wound after the first half of the primary is wound OR after the secondary layer?
Thanx for your timely response, but let me ask you weather to do primary culculation first and then do secondry or to do secondary first and then primary for inverter chopper.
Usually inverters have a push pull topology for the primary as this is driven by low voltage, This will incorporate 2 primary windings one in series with the other. According to the number of turns in the primary then a simple sum will get the number of turns in the secondary. Let us say you have 4v per turn then it will become quite easy to figure out.
@@supersilve Sir.If i use AWG25*4 wire use what will be the frequency in calculation?Please explain i appreciate your channel it solve most of our problems. tnx
@@ifnzutech As I explained in the Video every diameter of wire has its maximum frequency of operation due to skin depth of the current. A shot at the chart can be found at 31:59. You can see that the maximum operation frequency for 25 AWG wire is 85Khz.
For invertor chopper it is best to wind the primary first as this can be put more easily on the flat bobbin surface. The secondary may consist of multiple wires and the winding may not be so flat.
@@supersilve Thanks sir for the quick reply my question is that if i use AWG 25×4 mean AWG 25 four wire it's frequency will b 85Khz or 85khz × 4 = 345 khz and when I'll calculate it i use 85khz or 345khz.
Nice work, you seem to know about coils. I am working on a generator and need help with choosing and winding the right coils for the machine would you help?
Thank you sir for your sharing of knowledge to all. I read all the public comment of this video. But I have a question that why we can't use the laminated iron core for high frequency? Thank you
For HB, FB, and push pull topologies at 45% duty on each 1/2 cycle we are already at 90% duty. However to regulate at a specific voltage you need to add around root 2 (x1.414 to the wanted regulated voltage)
Is the 1200 to 2000 gauss max flux range related to the material type? Where too low of a flux level for the material will mean you could have used a smaller size transformer for better size/weight efficiency? And likewise, more flux than that range will cause magnetic saturation of the ferrite core material as well as heavy power losses and risk of burning the magic smoke out of the transformer?
Regarding flux density I always make some reverse engineering when extracting cores from ATX psu. I will calculate the switching frequency according to the chip used noticing the timing capacitor and resistor values. I will count the number of turns in the primary of the core. This will give me a good approximate of the flux used and also the core material. I will then adjust according to the new frequency used.
@@supersilve oh, so it is a rule of thumb type estimate based off of your reverse engineering of the original schematic the part was in. Thank you for the info. I really appreciate your videos by the way. A lot of this stuff can be really hard to learn without seeing someone do it step by step. Thank you for the many hours you must have put in to make these.
It is the same formula. You have to find the cross sectional area of the ring core. Outside diameter less inside diameter. Divide by 2 and multiply by the height.
MR Silvio please reupload the actual winding video of this transformer! I think you deleted it. It was so informative and its rare to find a real handmade tutorial for ferrite tranformers like the procedure that was this video described! Thank you
i hope you do, this video was your first video i watched from your channel and i think was the motive for most of your suscribers! i was ready to try to build a coil winder with counter like the one you did! Anyway.Keep up the good work!
hi sir..thankyou for make this video..sir at your video you writ turn=58mm. how you do calculate this number please if you can describe it ...thankyou sir
at higher frequency you need less windings, and can use smaller transformer. you can even get 350 watts or more with 10 Khz. Does not matter much, just parts need fit like transformer material and inducttion.
thanks a lot for you but did you know the type of the ferrite material of this core or not and if i did not know the type of the material how i can choose the value of Bmax (max flux density)
If I would have known the core material I would have chosen a Bmax of 2000 guass instead as according to the frequency used it would have taken it quite easy. I played it safe and chose 1800 instead. Usually computer ATX smps uses an N87 or PC40 core.
In push pull topology you must use the full input voltage in the formula. If for example you are using 12v then the centre tap winding shall be 12v-0-12v.
For Secondary turn is it necessary to consider the frequency because i was thinking that 7 wires side by side for more amps to get is a lot. Can it may be made with some THICKER wire probably to reduce that numbers?
The wire gauge is selected according to the frequency of operation. This is due to the skin dept as current tend to travel on the outer part of the copper wire. The higher the frequency the thinner the wire should be. I just posted a link on the previous post for the copper wire table there you will find the maximum frequency for each wire gauge can handle . One also has to consider how the wires will fit in the bobbin. Remember that wire in a transformer cannot loose heat quickly due to it being warped on top of each other thus the current handling will be less. Usually 3 to 4amps per mm² for continuous rating and 6 to 7 amps per mm² for 50% duty cycle.
Hi Silvio. I've been watching this with a very big interest as I'm thinking of trying to build my own Boost Converter from 12V to 24V just to try it and is using this video as a tutorial, but I got some questions. What is Bmax? and how did you deside to go with the value 1200-2000? For the turns for both primary and secondary windings, why do you have more than one layer? how did you figure this number out? Wouldn't a full bridge topology be more efficient?
Well there is a guide as for half bridge it all depends on what frequency is used. The higher the frequency the lower the B Max. For 33Khz a B Max of 1800 Guass is just right. if the frequency was lower say 25Khz I will have gone for 2000 Guass. B is the number of magnetic lines in the core. B max is the highest B according to the input voltage. Mains voltage fluctuates and goes up and down higher voltage brings more flux in the core according to the number of turns in the trafo. In your case the calculation for a boost converter using only one switching transistor is somewhat different. If it is as I said you will also be needing a gap in the center leg of the core. The larger the gap the lower the permeability of the core. That calculation I used in the video is suitable only for full bridge, half bridge and push pull topology. If there is more than one layer for a single voltage then coupling between windings will be lower but due to the high current needed it had to be like that otherwise it will not fit. I got more than a 1000 watts with half bridge with a suitable core. Check my 1000 watts smps on you tube. I hope that helps.
I've been trying this but it won't work. Have no clue where the error is. If you feel like I'd love to see your calculation for a fullbridge 12V to 24V SMPS with about 1 or 2 amps output. 😉
hi very interesting, i am also finding a way to lower high voltage and frequency, this is a good example thank you :) i wonder what will be the output frequency of the 24v secondary? i am just a beginner and experimenting on high frequency drivers.
What exactly do you want hi or low frequency? The frequency of the 24v output is the same frequency of the primary of the smps . In the example I shown is 33KHz.
i am using high frequency high driver at 10-15 khz going through a high voltage transformer and i just want to tap another transformer to lower the frequency to give me lower voltage at lower frequency if possible 60hz, while keeping the high frequency high voltage running on the side.
What output voltage do you need. is it DC or AC? What are you going to power an amplifier charger etc. Maybe I can understand clearly what you really want?
Mr. Silvio, thank you for your video, I want to ask you what is the difference between the formulas to calculate transformers with nucleus of ferrite and that of the transformers of iron nuclos, because from what I see are very similar
I'm a little late asking this but when it comes to making a step down transformer rather than a step up does it matter whether i wrap the primary coil first or the secondary?
no not really but its good practice to put the longest winding in the bottom due to it being of finer wire gauge. The secondary in this case may be shorter but thicker and it will fit better on top. Thus like this the primary will be neat and flat on the bottom.
Hello Friend, I congratulate you on the video, I have a question, how to calculate the power of the ferrite transformer with square or circular core, thank you
hi sir i saw your video that was realy good..sir i want make switching trans with 220Vin and +17v 0 -17v and i dont know i must use of what type of ferrite and that must how type of wire for secendary and primary...pleas lead me thankyou
I guess you need your transformer for audio amplifier as I see you need a center tap voltage. For a switching power supply you must know the peak DC output voltage to make the necessary calculation. For audio purpose we usually make a non regulated smps. The size of the transformer depend on the power needed. If you need more information please give me more details.
@@supersilve hi mr silvio at first i want say thankyou for answer my question i send several message for several people but that people dont answer to me. so i realy realy thankyou for answer my question...sir for me it's hard that talk at this place...that is my insta page::exorcistmmt. and if you need my emil i can send it for you just enough you tell me..i need more information for make ferrite ...please lead me more sir...again i want thankyou
sir i dont understand secondery winding. cause amper calculation . how can calculate copper 0.6 = 2 amp ? . its not have on chart. and primary layer is grow and center is to big first calculate . first center area = 58 mm. what is secondary area ? where is gone 7 wires ? can u tell again that point ? thank u
@@supersilve yes, considering the total power, I cannot handle more than 5 amps and also please refer power handling chart and kindly do let me know your comment
You can calculate the amperage of wire from the area of the wire size for continuous rating you calculate the area of each wire at 4 amps per mm squared. If for example you have 0.5 mm dia wire you find the area 3.142 X 0.25 X 0.25 = 0.196 mm squared so 0.196 X 4 = 0.7 amps. if it is not for continuous rating you can multiply by 6 and even 8 if you have a fan blowing at the transformer. Normally for audio purposes it is multiplied by 6 as the load is not continuous when powering an amplifier for example. so 0.196 X 6 = 1.17 amps now dividing this with with the input current comes 2.25 / 1.17 = 1.92 wires so you use 2 wires side by side to wind your primary winding
thank you verry much for the reply, actually i want to design step up push pull converter (300 v DC to 6kv pp AC) for later multiplied to 30kV DC, my question, is it possible to use ETD59 core?
thank you silvio, just to good understanding, if I have 320 volts as maximum input voltage, so that each primary windings is under 320V (i.e. 320v .0 .320v) which implies that in the calculation of primary winding turns I take 320*10^8/(4*33000*bmax*Ae), or take the nominal voltage?
In that case you would not use push pull topology but full bridge, and you will only have one winding for 320v. Push pull for high voltages is not suitable as it takes a lot of space in the transformer.
Dear sir, thanks for such an informative video. I wanted to ask you that whether I can use the same calculation for getting HT output from transformer..? Thanks you in advance. 😊
Yes you can but be careful as the voltage gets higher there is more chance that the HT winding will spark over and short out. Square waves have a lot of DC content and tend to are more readily than sine waves.
The Bmax is normally taken between 1200G and 2000G for frequencies below 100Khz. For 33Khz 18000guass is suitable and if the frequency was lower I would have used a higher flux like 2000g or so.
If the type of core is known then it would be easier to select the proper core as each core type can handle specific frequencies. This will be known from the datasheet.
Could you please tell me how to calculate for step up inverter, for push pull topology and the core is EE65/32/27 and also what would be the core's maximum power, at what frequency??
@@supersilve Ok, Prof. No prob. But I really do enjoy the tutorial. It has given me alot of insights into this type of transformer. But here's one more request: Could you pleases post a tutorial on ETD Core transformer for car Amp?
@@clintondowner7612An ETD core is no different except the centre core is round. You measure the diameter and find the cross sectional area. CSA = PIE X Radius ²
Very good. thanks for sharing. I have subscribed to you. you are an experienced transformer designer. made everything clear. what is the size of the core? I have been looking for a core like that but cannot find it. thanks again
If the input voltage to the power supply was between 100V and 240V will the nominal voltage be: 240V -100V = 140V, 140/2 = 70V giving 100+70V = 170V RMS, 170V x 1.414 = 240V DC peak nominal voltage. If using half-bridge topology 240V/2 = 120V, if using full-bridge topology will it be 240V DC?
If the calculation for the primary turns had to be with a wide input voltage such as 100-240 then the calculation for the maximum input has to be considered or at least one has to calculate the maximum B at maximum voltage and see that this does not exceed limits otherwise there is a chance of saturation in the transformer. In return the secondary windings have to be calculated at the minimum input voltage so the desired output voltage can be maintained throughout all the input voltage range. Feedback is essential otherwise the output voltage will vary considerably. As far as half or full bridge it will be the same thing for calculation. Half bridge uses half rectified voltage full bridge uses the full voltage.
Usually the flux density varies according to operating frequency and also the type of core material used. For example at 20 Khz the flux is normally taken around 2000 gauss while at say 80 to 100 khz it is taken around 1200 gauss. The frequency used in this example is 30Khz so the flux density is lowered from that of the 20Khz range hence that is why I chosen 1800 Guass. Bmax is the maximum flux seen by the transformer at the highest input voltage. The flux will be lower at a lower input voltage. If you will work out the formula in the video and change a bit the values you will see how it changes.
Hi, I am using EE 65/32/27 F48 MMG core, so could you please tell me the maximum power that the core can handle and what would be the optimum frequency to get peak power output. I want to build it for 24 volt at the primary and 380-400 volt at the secondary. Please help me I am trying to get information regarding this but I am really not getting it so could you help me please!
What are you actually building? What power are you expecting? I suggest you try something on a smaller scale first till you get some experience, when going to high powers things are not simple as they seem to be.
Silvio De Leonardo Hi, I am building high frequency inverter using ferrite core transformer, and push pull topology, so I don't know how to calculate the optimum frequency for maximum power for my core so please help me. I am using 0.8mm diameter copper wire for winding primary and 0.4 mm diameter copper wire for winding secondary turns, but I don't know how to calculate turns for push pull topology
The design frequency depend on quite a few things to be considered. 1 the higher the frequency the more power you get from a given core but not all cores can handle high frequency. One other factor is the wire gauge to be used and how it fits in the core. The higher the frequency the wire diameter gets thinner due to the skin depth. At higher frequencies switching losses also have to be considered. Usually a frequency between 20 and 80Khz can be chosen and most cores can handle this frequency range.
hello Silvio, your video is very interesting, but could you please help me how to calculate power of Transformer, i mean, if i need transfer 500W, so i will need transformer which how many is square?
It all depend on the frequency used and the available window space to accomodate the copper wire according to the current involved in both primary and secondary. It also depend on typology used. Half, full and push pull use the 4 quadrants of the flux while a flyback only use 1 quadrant. The latter the core has to be larger to get the same power compared to half bridge for example.
What you intend can be done in the following way: Embobinas your common transformer, rectify the signal and pass through a reegulable inverter, there you get the cycles you want. The investor circuits you find in youtube
You can do this by measuring the center core. If it round you will find the area by using the formula Pie R^2. if it is square you measure the length and breath and multiply them together. Be sure to measure in cm and your answer is to be in cm^2 to fit in the formula.
![[430] How To Calculate Ferrite Core Maximum Power Handling to Design High Frequency Transformer](http://i.ytimg.com/vi/Fk2OeYY_poo/mqdefault.jpg)
![[430] How To Calculate Ferrite Core Maximum Power Handling to Design High Frequency Transformer](/img/tr.png)
Sir you have given each and every minute aspect of design of SMPS ferrite transformer. I have seen many tutorials in this regard but this is the most exhaustive explanation ever I seen.Thank you very much.
This is excellent and is very educational to someone just learning SMPS theory. Thank you for taking the time to make this video
Thank you very much Mr. Silvio de Leonardo, thatś a huge help. I have have some dificulties with the formulas but you made it quite easy to understand. Keep doing the good job ...
Very good explanation "Prosit" people like you make a difference. Thank you.
Excellent informative and practical break down of the design procedure, thank you.
Excellent video with crystal clear explanation of each concept at different stages of winding. Thanks...
sir explaination is very good and nice. speaking in english is easy to understand for me thank you very much.
Excellent tutorial.I think that it will be of great value to students and technicians.Thanks.
I've learned many things after your videos, thank you so much!
Thank you for your excellent explanation. I am sure that it will certainly be of great deal of help to many as it is to me.
OLÁ SILVIO !!! É MUITO FÁCIL DE ENTENDER SUAS EXPLICAÇÕES , POIS TUDO É ESCLARECIDO COM RICOS DETALHES , SEM NADA OMITIR .. MEUS PARABÉNS , E CONTINUE SEMPRE ASSIM !!!
Thank you very much Silvio De Leonardo. This is the best video on youtbe. so very good explanation. and English is very very good. well done. Thank you. :)
Thank you, very important information. You can also convert from meter to feet directly uisng this: 1m x 3.28feet/m=3.28feet.
Leonardo,this tutorial helped me much..thank you
Very Nice Video. Was looking for something like this for a long time.
you are so good on formulas,very good video very smart men,i love these type things.
Thank you for uploading this, very helpful.
Tank you very very goood i need underestand this work and you very good teacher
Great video. For a flyback topology in the primary turns calculation I should use 310V instead of 155V of the half bridge? Thank you very much.
Yes you can.
Great video. A good reminder. Silvio you promised to leave a link to the copper wire chart but forgot to do so.
I gave the link on top of the comments. You can stop the video on 32:17 and copy it from there.
Hi There. I was some busy with the smps, I have decided to use resonant version, one with current feedback so I have fast respons and still stability. Did go to 10 amps 65 x 65 who is more then enough, the smsps can do easely the music peaks who live short, and I do never play so loud, ears will be give up earlyer then the suppy. For the tubes a 100 watt (overkill) LCC resonant can do, (also for audio better) these can run very nicely also without a load, burst mode for llc is not what I want, the ripple get bad and I need clean amp because it is high end class hybrid.
The question now, LCC resonance do need a transformer calculation, and in all papers she just talk about N this is coupled with tank calculations, never I see how high induction will be only AC who is the load max and min. I presume the smps transformer needs to have these reactante with max and min load valeu?
I do not now if you did resonance stuff, for LLC I do have tools and can calculate for LCC not because it is a older system, but it is used for led,s because of the nice respons for that.
regards
Very good video . There is one thing missing . How to select the magnetic core ? It would be good to add a video covering this topic .
The feedback to the opto must NEVER be taken after the second LC filter. Supply can become unstable due to the extra phase shift.
Very nice explanation. Thank you for sharing.
Glad it was helpful!
This is very informative and the author left nothing out. Thanks.
Great video with very clear explanation. I subscribed and hope you will create more videos. :-)
To disassemble a transformer safely heat it up in boiling water for about 5 to 10 minutes, depending on its size.
It will not always work sometimes the cores are glued with hard epoxy resin and boiling will not dissolve it.
1. Formula Shown at Video time 10:15 will also work for a uncut Ring/Toroidal core?
2. What will be the rough B max value we should consider for uncut Ring Core?
B max will change according to frequency used 2000 guass at 20Khz and 1200 guass at 100khz. As for the ring core you can calculate the core area and plug it in the formula. Make sure that it is not a powdered iron core as it is not suitable. They act as core with air gap.
Thanks sir I understand very well . thak you very much your lesson. bye
Here is the link for the Copper wire table
diyaudioprojects.com/Technical/American-Wire-Gauge/
One can also pause the video at 32:17 and copy it from there. Please note that the table is not downloadable however a screen shot can be taken and then printed.
Thanks for the video. Very helpful.
Thank you very much for clear calculations. ....may i have one of your publication about this caluculations....thanks.
Thank you for this really good video on transformer winding calculations. I was just wondering whether the auxiliary coil layer would be wound after the first half of the primary is wound OR after the secondary layer?
Aux windings are not so important and can be wound after the main secondary before the last half of the primary
Silvio De Leonardo Thanks man! 👍
Thanx for your timely response, but let me ask you weather to do primary culculation first and then do secondry or to do secondary first and then primary for inverter chopper.
Usually inverters have a push pull topology for the primary as this is driven by low voltage, This will incorporate 2 primary windings one in series with the other. According to the number of turns in the primary then a simple sum will get the number of turns in the secondary. Let us say you have 4v per turn then it will become quite easy to figure out.
@@supersilve Sir.If i use AWG25*4 wire use what will be the frequency in calculation?Please explain i appreciate your channel it solve most of our problems. tnx
@@ifnzutech As I explained in the Video every diameter of wire has its maximum frequency of operation due to skin depth of the current. A shot at the chart can be found at 31:59. You can see that the maximum operation frequency for 25 AWG wire is 85Khz.
For invertor chopper it is best to wind the primary first as this can be put more easily on the flat bobbin surface. The secondary may consist of multiple wires and the winding may not be so flat.
@@supersilve Thanks sir for the quick reply my question is that if i use AWG 25×4 mean AWG 25 four wire it's frequency will b 85Khz or 85khz × 4 = 345 khz and when I'll calculate it i use 85khz or 345khz.
great video. How can I calculate the size of the transformer core for the given power that is 120watt?
Nice work,
you seem to know about coils. I am working on a generator and need help with choosing and winding the right coils for the machine would you help?
Thank you sir for your sharing of knowledge to all. I read all the public comment of this video. But I have a question that why we can't use the laminated iron core for high frequency?
Thank you
A laminated core is not suitable for high frequency it only can handle up to 400Hz.
@@supersilve Thank you sir
What about the max 90% (2 x 45%) PWM of the SG3525 outputs. Does that not also need to be added as another 10% headroom?
For HB, FB, and push pull topologies at 45% duty on each 1/2 cycle we are already at 90% duty. However to regulate at a specific voltage you need to add around root 2 (x1.414 to the wanted regulated voltage)
Is this transfor calculation is same for same output voltage but dufferent circuit?
if i am using ee55 ferrite transformer at 100khz frequency and b max i think would be around 900 than what should be the volt per turn?
thanks
Is the 1200 to 2000 gauss max flux range related to the material type? Where too low of a flux level for the material will mean you could have used a smaller size transformer for better size/weight efficiency? And likewise, more flux than that range will cause magnetic saturation of the ferrite core material as well as heavy power losses and risk of burning the magic smoke out of the transformer?
Regarding flux density I always make some reverse engineering when extracting cores from ATX psu. I will calculate the switching frequency according to the chip used noticing the timing capacitor and resistor values. I will count the number of turns in the primary of the core. This will give me a good approximate of the flux used and also the core material. I will then adjust according to the new frequency used.
@@supersilve oh, so it is a rule of thumb type estimate based off of your reverse engineering of the original schematic the part was in. Thank you for the info.
I really appreciate your videos by the way. A lot of this stuff can be really hard to learn without seeing someone do it step by step. Thank you for the many hours you must have put in to make these.
Excellent video . Can you make a similar for ferrite toroidal? . Excellent job once again
It is the same formula. You have to find the cross sectional area of the ring core.
Outside diameter less inside diameter. Divide by 2 and multiply by the height.
MR Silvio please reupload the actual winding video of this transformer! I think you deleted it. It was so informative and its rare to find a real handmade tutorial for ferrite tranformers like the procedure that was this video described!
Thank you
I will upload a better one in the future
i hope you do, this video was your first video i watched from your channel and i think was the motive for most of your suscribers! i was ready to try to build a coil winder with counter like the one you did! Anyway.Keep up the good work!
hi sir..thankyou for make this video..sir at your video you writ turn=58mm. how you do calculate this number please if you can describe it ...thankyou sir
Very useful to us Sir ..
How you can get 350W with 33Khz?
i undertand that at higher frequency, more power can be transferred from primary to secondary
at higher frequency you need less windings, and can use smaller transformer. you can even get 350 watts or more with 10 Khz. Does not matter much, just parts need fit like transformer material and inducttion.
thanks a lot for you but did you know the type of the ferrite material of this core or not and if i did not know the type of the material how i can choose the value of Bmax (max flux density)
If I would have known the core material I would have chosen a Bmax of 2000 guass instead as according to the frequency used it would have taken it quite easy. I played it safe and chose 1800 instead. Usually computer ATX smps uses an N87 or PC40 core.
nice video. Can I use this formula for fly back converter (smps) as well?
No the formula is only suitable for half bridge, full bridge and push pull converter.
Hi Silvio ; very nice -- Just a question can we apply (( push-pull topology = 1/2 Nominal voltage ))
In push pull topology you must use the full input voltage in the formula. If for example you are using 12v then the centre tap winding shall be 12v-0-12v.
For Secondary turn is it necessary to consider the frequency because i was thinking that 7 wires side by side for more amps to get is a lot. Can it may be made with some THICKER wire probably to reduce that numbers?
The wire gauge is selected according to the frequency of operation. This is due to the skin dept as current tend to travel on the outer part of the copper wire. The higher the frequency the thinner the wire should be. I just posted a link on the previous post for the copper wire table there you will find the maximum frequency for each wire gauge can handle . One also has to consider how the wires will fit in the bobbin. Remember that wire in a transformer cannot loose heat quickly due to it being warped on top of each other thus the current handling will be less. Usually 3 to 4amps per mm² for continuous rating and 6 to 7 amps per mm² for 50% duty cycle.
@@supersilve thank you
Hi Silvio. I've been watching this with a very big interest as I'm thinking of trying to build my own Boost Converter from 12V to 24V just to try it and is using this video as a tutorial,
but I got some questions.
What is Bmax? and how did you deside to go with the value 1200-2000?
For the turns for both primary and secondary windings, why do you have more than one layer? how did you figure this number out?
Wouldn't a full bridge topology be more efficient?
Well there is a guide as for half bridge it all depends on what frequency is used. The higher the frequency the lower the B Max. For 33Khz a B Max of 1800 Guass is just right. if the frequency was lower say 25Khz I will have gone for 2000 Guass. B is the number of magnetic lines in the core. B max is the highest B according to the input voltage. Mains voltage fluctuates and goes up and down higher voltage brings more flux in the core according to the number of turns in the trafo. In your case the calculation for a boost converter using only one switching transistor is somewhat different. If it is as I said you will also be needing a gap in the center leg of the core. The larger the gap the lower the permeability of the core. That calculation I used in the video is suitable only for full bridge, half bridge and push pull topology. If there is more than one layer for a single voltage then coupling between windings will be lower but due to the high current needed it had to be like that otherwise it will not fit. I got more than a 1000 watts with half bridge with a suitable core. Check my 1000 watts smps on you tube.
I hope that helps.
I'll check that out, thanks :)
I've been trying this but it won't work. Have no clue where the error is.
If you feel like I'd love to see your calculation for a fullbridge 12V to 24V SMPS with about 1 or 2 amps output. 😉
Thanks so much, very good explanation , can you please explain how you get the value of Bmax
The B max should be between 1200 to 2000 gauss depending on the core material and power absorbed from trafo
hi very interesting, i am also finding a way to lower high voltage and frequency, this is a good example thank you :) i wonder what will be the output frequency of the 24v secondary?
i am just a beginner and experimenting on high frequency drivers.
What exactly do you want hi or low frequency? The frequency of the 24v output is the same frequency of the primary of the smps . In the example I shown is 33KHz.
i am using high frequency high driver at 10-15 khz going through a high voltage transformer and i just want to tap another transformer to lower the frequency to give me lower voltage at lower frequency if possible 60hz, while keeping the high frequency high voltage running on the side.
What output voltage do you need. is it DC or AC? What are you going to power an amplifier charger etc. Maybe I can understand clearly what you really want?
Mr. Silvio, thank you for your video, I want to ask you what is the difference between the formulas to calculate transformers with nucleus of ferrite and that of the transformers of iron nuclos, because from what I see are very similar
Yes they are in fact they just differ a little in the constant when using square wave (4) or sine wave (4.44)
thank you, God bless you
Thankyou very much for helpful email 💝
great demonstration friend
I'm a little late asking this but when it comes to making a step down transformer rather than a step up does it matter whether i wrap the primary coil first or the secondary?
no not really but its good practice to put the longest winding in the bottom due to it being of finer wire gauge. The secondary in this case may be shorter but thicker and it will fit better on top. Thus like this the primary will be neat and flat on the bottom.
Hello Master.
1 doubt.
Where did you get this 1414 from
1.414 = square root of 2
Muchas gracias amigo! me ayudó mucho.
What is the number of first and second AWG wires, EE65 Inverse from 12v to 220v? Thank you
How you calculated from Windows area this core is suitable for 350 watt can you explain in deep. Or any excel sheet for calculation pls share with me
Hello Friend, I congratulate you on the video, I have a question, how to calculate the power of the ferrite transformer with square or circular core, thank you
Leonardo, You are using Half Bridge Topology So voltage is 155v , But if I use Flyback Topology Then what will be the voltage?
hi sir i saw your video that was realy good..sir i want make switching trans with 220Vin and +17v 0 -17v and i dont know i must use of what type of ferrite and that must how type of wire for secendary and primary...pleas lead me thankyou
I guess you need your transformer for audio amplifier as I see you need a center tap voltage. For a switching power supply you must know the peak DC output voltage to make the necessary calculation. For audio purpose we usually make a non regulated smps. The size of the transformer depend on the power needed. If you need more information please give me more details.
@@supersilve hi mr silvio at first i want say thankyou for answer my question i send several message for several people but that people dont answer to me. so i realy realy thankyou for answer my question...sir for me it's hard that talk at this place...that is my insta page::exorcistmmt. and if you need my emil i can send it for you just enough you tell me..i need more information for make ferrite ...please lead me more sir...again i want thankyou
Love it. Thanks for the video.
sir i dont understand secondery winding. cause amper calculation . how can calculate copper 0.6 = 2 amp ? . its not have on chart. and primary layer is grow and center is to big first calculate . first center area = 58 mm. what is secondary area ? where is gone 7 wires ? can u tell again that point ? thank u
Nice explanation Engineer, but @ 33khz and u using EI33 core so i think it cant handle 14amps and core gets toomuch heat losses
It depends on the total power not the current. The core is capable for 350w@33khz
@@supersilve yes, considering the total power, I cannot handle more than 5 amps and also please refer power handling chart and kindly do let me know your comment
your chart is saying 0.6mm wire can handle only 0.92 amps, but for 350 watts you need atleast 2.25 amps at 155V primary, how is it possible...?
You can calculate the amperage of wire from the area of the wire size for continuous rating you calculate the area of each wire at 4 amps per mm squared. If for example you have 0.5 mm dia wire you find the area 3.142 X 0.25 X 0.25 = 0.196 mm squared so 0.196 X 4 = 0.7 amps. if it is not for continuous rating you can multiply by 6 and even 8 if you have a fan blowing at the transformer. Normally for audio purposes it is multiplied by 6 as the load is not continuous when powering an amplifier for example. so 0.196 X 6 = 1.17 amps now dividing this with with the input current comes 2.25 / 1.17 = 1.92 wires so you use 2 wires side by side to wind your primary winding
Hi,
What is the ferrite tesla value?
Thanks for the video.
0.18 tesla
Excellent tutorial.
Glad you liked it!
if i want to use the push-pull topology, what is the change in laws should be considered?
Not much really but push pull topology has 2 primary windings (Ex 12-0-12) in the calculation you can put 12 X 10^8 instead of 155 etc
thank you verry much for the reply, actually i want to design step up push pull converter (300 v DC to 6kv pp AC) for later multiplied to 30kV DC, my question, is it possible to use ETD59 core?
Yes it is possible to use an ETD59 core
thank you silvio, just to good understanding, if I have 320 volts as maximum input voltage, so that each primary windings is under 320V (i.e. 320v .0 .320v) which implies that in the calculation of primary winding turns I take 320*10^8/(4*33000*bmax*Ae), or take the nominal voltage?
In that case you would not use push pull topology but full bridge, and you will only have one winding for 320v. Push pull for high voltages is not suitable as it takes a lot of space in the transformer.
Sir can we use this formula for inverter chopper if don't then how to calculate inverter chopper.
Yes
Dear sir, thanks for such an informative video. I wanted to ask you that whether I can use the same calculation for getting HT output from transformer..?
Thanks you in advance. 😊
Yes you can but be careful as the voltage gets higher there is more chance that the HT winding will spark over and short out. Square waves have a lot of DC content and tend to are more readily than sine waves.
@@supersilve thanks sir, well noted. 🙏
hi, thanks for de video very good, where you get the b-max number
The Bmax is normally taken between 1200G and 2000G for frequencies below 100Khz. For 33Khz 18000guass is suitable and if the frequency was lower I would have used a higher flux like 2000g or so.
thanks for answering, How to know what type of ferrite is used for each application?
If the type of core is known then it would be easier to select the proper core as each core type can handle specific frequencies. This will be known from the datasheet.
Could you please tell me how to calculate for step up inverter, for push pull topology and the core is EE65/32/27 and also what would be the core's maximum power, at what frequency??
muy bueno. tiene un like y me he suscrito a su canal. gracias
Hey Professor Leonardo, Could u please post a schematic to which this transformer can work?
I do not have a schematic for this tutorial. I made this video for learning purposes
@@supersilve Ok, Prof. No prob. But I really do enjoy the tutorial. It has given me alot of insights into this type of transformer. But here's one more request: Could you pleases post a tutorial on ETD Core transformer for car Amp?
@@clintondowner7612An ETD core is no different except the centre core is round. You measure the diameter and find the cross sectional area. CSA = PIE X Radius ²
Sir, can give the link to download the data sheet of AWG/SWG wires with their current carrying capacity
Search on the following: wire table maximum frequency for skin
Thanks for this video!
sir, how do you get the magnatic flux for ferrite trafo. which is 4. i get confused.
The number 4 is part of the formula for pulses having dc content (square wave for example) for sine wave you use 4.44 instead.
Super sir thank you so much
Very good. thanks for sharing. I have subscribed to you. you are an experienced transformer designer. made everything clear. what is the size of the core? I have been looking for a core like that but cannot find it. thanks again
The core size is an E I 33
thanks.
amigo si utilizo un hilo q soporta una frecuencia y Hz y sar en un derrumbe para una frecuencia Khz puede dar algún problema
can i use same method for fly back converter transformer?!
No you cannot, calculations for flyback are somewhat different and more complex.
thanks for your response can you Can you give me a tutorial link? or any thing can be help for me?@@supersilve
Go to Haseeb electronics on youtube and search his videos. You will surely find a tutorial that you need.
If the input voltage to the power supply was between 100V and 240V will the nominal voltage be: 240V -100V = 140V, 140/2 = 70V giving 100+70V = 170V RMS, 170V x 1.414 = 240V DC peak nominal voltage. If using half-bridge topology 240V/2 = 120V, if using full-bridge topology will it be 240V DC?
If the calculation for the primary turns had to be with a wide input voltage such as 100-240 then the calculation for the maximum input has to be considered or at least one has to calculate the maximum B at maximum voltage and see that this does not exceed limits otherwise there is a chance of saturation in the transformer. In return the secondary windings have to be calculated at the minimum input voltage so the desired output voltage can be maintained throughout all the input voltage range. Feedback is essential otherwise the output voltage will vary considerably. As far as half or full bridge it will be the same thing for calculation. Half bridge uses half rectified voltage full bridge uses the full voltage.
Thank you for the clarification
Could you please send me the link for that copper wire chart??
You can pause the video at 32.18 and copy it
Silvio De Leonardo yeah sorry, I got it know thank you very much
Muy bueno amigo... Me gustaría saber cómo optienes número de hilos de los primarios y secundarios...espero no sea mucha molestia gracias.
Puede traducir los subtítulos del video a su idioma y comprenderá cómo calcular el número de turnos
can you tell me why did you take flux density as 1800 gauss ???
and why Bmax is between 1200-2000 gauss ?
Usually the flux density varies according to operating frequency and also the type of core material used. For example at 20 Khz the flux is normally taken around 2000 gauss while at say 80 to 100 khz it is taken around 1200 gauss. The frequency used in this example is 30Khz so the flux density is lowered from that of the 20Khz range hence that is why I chosen 1800 Guass. Bmax is the maximum flux seen by the transformer at the highest input voltage. The flux will be lower at a lower input voltage. If you will work out the formula in the video and change a bit the values you will see how it changes.
Hi, I am using EE 65/32/27 F48 MMG core, so could you please tell me the maximum power that the core can handle and what would be the optimum frequency to get peak power output.
I want to build it for 24 volt at the primary and 380-400 volt at the secondary.
Please help me I am trying to get information regarding this but I am really not getting it so could you help me please!
What are you actually building? What power are you expecting? I suggest you try something on a smaller scale first till you get some experience, when going to high powers things are not simple as they seem to be.
Silvio De Leonardo Hi,
I am building high frequency inverter using ferrite core transformer, and push pull topology, so I don't know how to calculate the optimum frequency for maximum power for my core so please help me.
I am using 0.8mm diameter copper wire for winding primary and 0.4 mm diameter copper wire for winding secondary turns, but I don't know how to calculate turns for push pull topology
Very good video . Thank you .
How to calculate the design frequency
The design frequency depend on quite a few things to be considered. 1 the higher the frequency the more power you get from a given core but not all cores can handle high frequency. One other factor is the wire gauge to be used and how it fits in the core. The higher the frequency the wire diameter gets thinner due to the skin depth. At higher frequencies switching losses also have to be considered. Usually a frequency between 20 and 80Khz can be chosen and most cores can handle this frequency range.
From where can I buy the core? Please reply.
you can try aliexpress or e-bay
hello Silvio, your video is very interesting, but could you please help me how to calculate power of Transformer, i mean, if i need transfer 500W, so i will need transformer which how many is square?
It all depend on the frequency used and the available window space to accomodate the copper wire according to the current involved in both primary and secondary. It also depend on typology used. Half, full and push pull use the 4 quadrants of the flux while a flyback only use 1 quadrant. The latter the core has to be larger to get the same power compared to half bridge for example.
please make a video for push pull transformer winding for 12-0-12 or 24-0-24 to out put 220V AC any watts.
Is it possible to make 250/25, 50Hz, 100 watt ferrite core transformer? If possible please let me know.
Ferite transformers are to work on high frequency and cannot work on 50Hz
What you intend can be done in the following way: Embobinas your common transformer, rectify the signal and pass through a reegulable inverter, there you get the cycles you want. The investor circuits you find in youtube
you need iron cored transformer
Content quality is too good, but could you please make a video little clear and with pen or sketch?
thank you so much for this video.
Can apply this calculation on teroidal transformer
Sermad Sajjad yes
Silvio help! i cant register on your website... i have a problem with the random question i guess... it doesnt accept it
Which website are you referring to?
How I can find out core area of ferrite toroidal of core ?
You can do this by measuring the center core. If it round you will find the area by using the formula Pie R^2. if it is square you measure the length and breath and multiply them together. Be sure to measure in cm and your answer is to be in cm^2 to fit in the formula.