selection of wire size(guage) of ferrite core transformer of smps inverter & charger

[aqildad]

selection of wire size(guage) of ferrite core transformer of smps inverter & charger

please guide me how to select wire size of smps inverter and charger .

 

[KlausST]

Re: selection of wire size(guage) of ferrite core transformer of smps inverter & cha

H,

First you have to decide how much energy you need to be stored in the magnetic field.
With the desired frequency you select the core material
Then you have to select the core size.
With an air gap in the cor you can adjust saturation bevior.
Now you get the AL value from the core datasheet. With it and the desired inductivity you can calculate the number of windings.

Now there are several points to calculate the wire gauge.
With the area for windings of the core and the number of windings you can estimate the max possible wire diameter.
( leave a lot of area for air, isolaton and crossing of wires)
With the length of wire per winding and the number of windings and the wire diameter you can calculate the wire resistance.
With the expected average current and the resistance you can calculate the winding's power loss.

With the power loss you can decide wether you tend to use a larger or smaller wire diameter, mabe you need another core size.

Hope that helps.
Klaus

 

[aqildad]

Re: selection of wire size(guage) of ferrite core transformer of smps inverter & cha

for example my load is 300watt
etd39
oscillation frequency 50khz

what should be the wire size ??? this is my transformer from tahmid blog https://tahmidmc.blogspot.com/2012/12/ferrite-transformer-turns-calculation.html

 

[KlausST]

Re: selection of wire size(guage) of ferrite core transformer of smps inverter & cha

Hi,

300W can be 300V and 1A or 1V and 300A.

As you know for 300A you need a way larger diameter than for 1A.

Klaus

- - - Updated - - -

Hi,

I just had a look at thamids description.
It seems to be very detailed. Try to calculate it this way. If you have any problems then ask in detail.

Always a good source of information is the manufacturer.
For the ETD i think it is EPCOS. They surely have good application notes.

Klaus

Did you look for "online transformer calculator" ?

 

[FvM]

Re: selection of wire size(guage) of ferrite core transformer of smps inverter & cha

Epcos has the Ferrite Magnetic Design Tool to support the calculations