Transformer Winding

[PA3041]

Hi Team,

Please advice to convert the transformer in the picture one to transformer in the picture two

I need to convert round type transformer to squire type transformer
What type of calculations that I need to use

Thanks in advance

 

[betwixt]

The first picture shows an adjustable transformer with different primary and secondary using Litz wire. The second picture is of a conventional E-I cored transformer with single core copper wire. They appear to be for different purposes so it is unlikely one could be substituted for the other. More information on the application might help.

Brian.

 

[PA3041]

The first picture shows an adjustable transformer with different primary and secondary using Litz wire. The second picture is of a conventional E-I cored transformer with single core copper wire. They appear to be for different purposes so it is unlikely one could be substituted for the other. More information on the application might help.

Brian.

Thanks for prompt reply

The first picture transformer is used in the ultrasonic cleaner which is discontinued model, So we need to change the transformer with available model, Supplier does not support further as it is discontinued, Few bobbin has been damaged at the rewinding

 

[FvM]

The first "transformer" is comprised of loosely coupled inductors and can't be made with a closed magnetic path core, e.g. E core. First step would be to identify the parameters (self and mutual inductance, wire cross section, litz wire stranding). The bobbins can be remade with high temperature plastic 3D print.

 

[Easy peasy]

@PA3041, the quickest way here would be to find a real power electronics engineer in your area and ask him/her to measure the Lmag, Llk, and coupling coefficients of the Tx, also the Rac, RDC of the pri and sec,

also the self res freq for pri and sec ( SRF ) - then it may be possible for that person or a gifted engineer on this forum - or elsewhere - to design essentially the same transformer on a gapped long E core with a split bobbin - with litz wire to get close to picture number one in performance ...

 

[PA3041]

The first "transformer" is comprised of loosely coupled inductors and can't be made with a closed magnetic path core, e.g. E core. First step would be to identify the parameters (self and mutual inductance, wire cross section, litz wire stranding). The bobbins can be remade with high temperature plastic 3D print.

Your solution is supper, We have a 3D printer but we did not remember it . Thanks a lot

--- Updated Oct 29, 2022 ---

@PA3041, the quickest way here would be to find a real power electronics engineer in your area and ask him/her to measure the Lmag, Llk, and coupling coefficients of the Tx, also the Rac, RDC of the pri and sec,

also the self res freq for pri and sec ( SRF ) - then it may be possible for that person or a gifted engineer on this forum - or elsewhere - to design essentially the same transformer on a gapped long E core with a split bobbin - with litz wire to get close to picture number one in performance ...

This is the concrete solution but hard to find a proper engineer.
Can you please advice what is the best transformer comparing E core and split bobbin core for ultrasonic cleaner

--- Updated Oct 29, 2022 ---

@PA3041, the quickest way here would be to find a real power electronics engineer in your area and ask him/her to measure the Lmag, Llk, and coupling coefficients of the Tx, also the Rac, RDC of the pri and sec,

also the self res freq for pri and sec ( SRF ) - then it may be possible for that person or a gifted engineer on this forum - or elsewhere - to design essentially the same transformer on a gapped long E core with a split bobbin - with litz wire to get close to picture number one in performance ...

This is the concrete solution but hard to find a proper engineer.
Can you please advice what is the best transformer comparing E core and split bobbin core for ultrasonic cleaner

 

[Easy peasy]

there is no other approach unless you are very familiar with the circuit the Tx is in ...