FlapJack
Full Member level 6
It is not reverse logic. With low input voltage the controller has to raise the duty cycle to compensate. With high input voltage the controller cuts the duty cycle back.
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It is not reverse logic. With low input voltage the controller has to raise the duty cycle to compensate. With high input voltage the controller cuts the duty cycle back.
normal current density for cooper is 4...6 A /mm^2, but considering pelicular(/skin) effect at high frequencies you have to increase cross section by some xy % (actually there is a formula to calculate the skin effect depth for given frequency , and actually an online calculator also :thinker: )
(and probably after you check the maximum admissible current for the wire gauge you choose , you go back to see if you still have the inductance you need for the coil :lol: )
etd59
winding width ferroxcube = 41.2mm = 1.6220" - .236" total margin 1/2 on each side (3mm each side) = 1.386" winding width (35.2mm).
Primary, as Warpspeed said use copper foil. .008" is the proper thickness cut it at 35mm width and use 4 turns centered on bobbin.
Secondary, I think you should use 2 secondary winding's of 36 turns each. This will let you use a 2 diode center tapped output. For the wire you will have to make a poor mans litz wire, 25 strands of 35awg double insulated magnet wire, twisted approximately 1/2 turn per CM. You should have just enough room for 36 turns centered on the bobbin to fill the 35mm area.
1, Wind on bobbin 1st 36 turn secondary.
2, Add 3 layers of tape as wide as the bobbin is.
3, Add 4 turn primary winding.
4, Add 3 layers of tape as wide as the bobbin is.
5, Add 2nd 36 turn secondary.
6, Add 2 layers minimum of tape, as wide as the bobbin is.
There are such things as screens and Faraday shields that can go between the primary and secondary but most people do not use them.
I am not sure of a good way to get the connection out for the copper foil. Maybe someone else has a good idea.
Lets see if others have any better ideas or corrections and go from there.
Ebay has some copper foil that will work.
.008" foil = .2mm
Search Ebay for this.
Pure Copper Cu Metal Sheet Foil 0.2 x 100 x 1000 mm
Pure Copper Cu Metal Sheet Foil 0.2 x 100 x 500 mm
You need 289mm minimum length, to go around 4 turns.
Don't worry about wire gauges , just put there the thickest wire you can get from the neighbors fence :grin: (kidding, leave the fence alone) just to be shore , you probably have enough space between core columns , plus you don't need extra isolation between layers (you are not building a 220/110 kV transformer )
E-Design, i see some problems here. Each secondary has to be 330v for a full bridge center tap to work.
I am having trouble reading the specs, for instance the foil layer looks like it is saying an equivalent of 10awg but i see no foil thickness or width spec that made any sense.
From the program, Wire Height (cm) = 12.70m, what could that possibly mean?
The width seems wrong to me also, Wire Width (cm): 4.297, here i assume that the total width of the bobbin is 4.297mm, but this leaves no margin.
Also, for the secondary's, what is the difference between turns and turns per layer? One says 16 and the other is 18.
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E-Design, one more thing, we were using 39vdc for V in low on primary.