Ferrite Core Transformer Calculation Software

[Tamar Navratil]

Nowcores are of varied materials such as ferrites, steel, silicon, and many more. This article will focus solely on ferrite cores and expound on the different types, benefits, and applications. Additionally, we may give other knowledge that may be of importance to you.

Often, the magnetic ferrite cores have a combination of manganese, zinc, nickel compounds, and iron oxides. Since the compounds have low coercivity, they fall under soft ferrites. Ferrite core types comprise shell, toroidal, cylindrical, and closed-core.

Ferrite core transformers usually have a higher demand when compared to iron core transformers. The ferrite transformers have advantages, including resistance to elevated currents, low hysteresis losses, and no lamination required.

ETD cores; First, we have the ETD cores with minimum winding resistance at their center post. The winding resistance allows optimization of dimensions for increased power efficiencies. Furthermore, they suit inductors and power transformers efficiently.

EER cores; Secondly, there are EER cores with a round center post feature. Most times, the round center post will permit a shorter winding path length when compared to a square center post.

E, I core; Its feature is a bobbin winding. And you can assemble it with ease. E, I core uses are; inverter transformers, broadband, power, converters, telecom inductors, and differentials.

Different applications and core types have varying names and topologies based on the circuit design. Some of the topologies include flyback, push-pull, half-bridge, and shell-type. Nonetheless, when designing any ferrite transformer with any topology form, consider the shape, unit cost, optimum temperature, size, and frequency. The mentioned points should uphold the transformer by minimizing core losses, providing electrical isolation, and preventing core saturation.

All in all, ferrite core transformers are the best option when considering high-frequency applications since they have efficient performance. The transformers have high magnetic permeability, high coercivity, and they conduct low electrical power. The high-frequency applications include switched-mode power supply, noise filters, RF (radio frequency) inductors, transformers, etc.

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The Power Chart characterizes the power handling capacity of each ferrite core based upon the frequency of operation, the circuit topology, the flux level selected, and the amount of power required by the circuit. If these four specifics are known, the core can be selected from the Typical Power Handling Chart.

The power handling capacity of a transformer core can also be determined by its WaAc product, where Wa is the available core window area, and Ac is the effective core cross-sectional area. Using the equation shown below, calculate the WaAc product and then use the Area Product Distribution (WaAc) Chart to select the appropriate core.

For my design, I have used Bmax as 35mT, or 3500 gausses. I have calculated primary using this formula.(0.5 * Vin * 10^8)/ 4 * F * Bmax * Cross-section-Area). I have added 0.5 cause my design is Half Bridge. My switching Frequency is 50Khz. And my cross-section area is 2.9cm^2. So the result is 3.69 turn, so have used 4 turns in primary using 6mm square Wire. I need not more than 28mA in Secondary, so I have used 37AWG wire. And the secondary turn I have calculated using *(Vs/Vp)Np= 2666 Turns in secondary. But I have used 3000 turns in secondary.

Now the problem I am facing is while my secondary is at 0/NO loads,my Primary current is drawing 15-ampere peak at 40 volts RMS. When I am trying to give more voltage in the primary, the primary is drawing more current proportional to the primary voltage. Even when I am trying to generate an ARC in secondary the primary peak current is the remain the same. At 40 volt RMS my secondary should generate 4*666.66 = 26640 Volt. But the arc is only 1cm Long. My power is supply can provide up to 3KW.

Why my ferrite transformer drawing 15amp peak at 40-volt RMS at NO loads ?, I mean when the secondary is not generating any ARC or the secondary wires are not even close? I have measured the secondary wire resistance. The resistance is 535 ohms.

If you are trying to get a 100 kV DC output then limit your transformer to producing an RMS output in the mid-kV range i.e. 3 to 5 kV AV and then use a Cockcroft-Walton voltage multiplier on the output that is oil-immersed and I don't mean cooking oil.

The reason I point out about limiting the transformer AC output is that with the number of turns needed, the insulation between secondary layer and the leakage inductance, you'll just about avoid hitting the self-resonant frequency of the transformer. If you hit SRF then you'll get really big problems that you'll never control.

I once designed a 50 kV power supply for an X-ray machine and plenty of days I got cold feet and stress during initial prototype testing. It could produce 4 mA but it was a scary beast. I had my load (and CW multiplier) immersed in a big oil bath and you could see the oil churning with the volts when I was operating at full wack. You should never do this on your own - you need someone in the room with you with a long stick that can press the on-off button on the DC power supply in case you start to fry.

In this article, you will learn how to calculate the turns ratio of a ferrite core transformer for high-frequency switch mode power supply inverters. High-frequency ferrite core transformers are used in almost every power electronics circuit, such as inverters and pure sine wave inverters. They are used to boost up or step up the low DC voltage of a battery and other DC sources, like solar panels. Ferrite core transformers are also used in isolated DC to DC converters to step down or step up the DC voltage. For example, in an isolated buck converter, it is used to step down the DC voltage, and in an isolated boost converter, they are used to step up the DC voltage. In this article, we will learn how to calculate the turns ratio of a high-frequency ferrite core transformer with examples.

A Ferrite Core Transformer is a type of transformer that uses a ferrite core instead of an iron core. Ferrite cores are made from a mixture of iron oxide and other metals, and they have unique magnetic properties that make them suitable for use in high-frequency applications. Ferrite core transformers are commonly used in power electronics circuits, such as inverters and DC to DC converters, to step up or step down voltage levels. They are known for their high efficiency and compact size, making them ideal for applications where space and energy efficiency are important.

For example, in the boost-up stage we have two options to choose from in power electronics converters: push-pull topology and full bridge. I will explain both methods one by one. The turns ratio calculation formula and concept remain the same for both topologies. The only difference between the push-pull topology and the full bridge transformer design is that the push-pull ferrite core transformer requires a center tap in the primary winding. In other words, the push-pull transformer has twice the number of primary turns than the full bridge transformer.

As you know, battery voltage does not remain the same all the time. As the load on the battery increases, the battery voltage will be less than 12 volts. With no load and a fully charged battery, the battery voltage will be near 13.5 volts. Therefore, the input voltage is not constant, and we must consider it while calculating the turns ratio of the ferrite core transformer. The cutoff voltage for the battery is usually 10.5 volts. We can take it as the smallest possible value of the input voltage to boost up the DC converter. So, we have the following parameters now:

Where Npri is the number of primary turns and Nsc is the number of secondary turns. We have three known variables like turns ratio, which can be calculated by the above equation, input voltage, and output voltage. But we need to calculate the primary turns to find the secondary turn of a ferrite core transformer. The formula to calculate the primary turns for a ferrite core transformer is given below:

So the calculated value of Bmax is 1600G, which is within the acceptable range of the maximum flux density. This means we can take Npri = 3 for further calculations. The primary number of turns for the push-pull ferrite center-tap transformer is 3 turns + 3 turns. In any design, you will need to adjust the value of Npri if it is in fraction. You can easily adjust it. But you need to check the value of Bmax every time. We start with an assumed value of Bmax and calculate Npri. But you can also start with an assumed value of Npri and check the value of the maximum flux density Bmax. For example, suppose a value of Npri = 1 and check the value of Bmax, and keep repeating this process until it falls within an acceptable range.

So, the transformer must be able to supply a 330-volt output with an input range of 13.5 volts to 10.5 volts. The maximum duty cycle for PWM is 98%, leaving the remaining 2% for dead time. During the minimum possible input voltage, the duty cycle will be at its maximum. At a maximum duty cycle of 98%, the input voltage to the transformer is 0.98 * 10.5 = 10.29 volts.

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