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
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 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?