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160V/24V smps transformer winding

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dawid5255252

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Hello, I want to design and wind transformer to smps with parameters:

INPUT: 160V / 4A
OUTPUT: 24 / 26,667A
POWER: 640W (this power is needed to start motor, constant power needed is 170W)
FREQ: 150kHz

I have disassembled PC power supply ATX 300W and get core EI-33C form it, like on screen below

Zdjęcie0834.jpg

And I have some questions:
1. What wire diameter should I use and how many windings should I apply each side (prim/sec)?
2. Is it possible to get 640W with this core and frequency?
 

I have calculated windings and the results are as follows:

PRIMARY: 17
SECONDARY: 3
TURNS RATIO: 5,667
Bmax: 1350G

I have a question about windings. Is it allowed to multiply it, for example 2x (prim 34, sec 6)?
I still don't know any relationship between wire diameter and frequency
 

Wire thickness depends on current. At high frequency, a thick wire causes losses due to eddy current so multitple strands of thin wires such as 1mm are used instead. Litz wire is the best which is more expensive.
Multiplying and keeping turn ratio the same will let it to work on lower frequencies but adding to resistive and inductive losses.
 
In my transformer I need about 2mm^2 for primary and 3mm^2 for secondary wire diameter. I deduce that I won't get 26A with freuency 150kHz, because wire will be too thick as you said.
Is it better idea to put:
PRIMARY: 34 turns / 1mm^2 diameter
SECINDARY: 6 turns / 1,5mm^2 diameter
That's what you mean?
 
Last edited:

The core you pulled out is not
gonna work go for ec49, ee59, edt59 etc or bigger
 
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