Design Of Low Voltage Step Down Transformer(220/30V,200VA)

Calculations For Design:

Te(Turns per volt)=1/4.44 x f x Bm x Ai
Te=3.5 for 200VA
Ai(Iron Core Area)=1/4.44 x 50 x 1.0 x 3.5
Ai=1287 mm2
We Are Selecting E-I Stamping:
Ki=Stacking Factor=0.9
Agi(Gross Core Area)=Ai/Ki
Agi=1287/0.9
Agi=1430 mm2
Width of central Limb=A = (Agi)^1/2 = (1430)^1/2 = 37.815mm

Turns Of Primary Winding:

T1=V1 x Te
T1=220 x 3.5=770 turns
Efficiency=86%

Current In Primary Winding:

I1=VA/(V1 x efficiency)
I1=200/220x0.86
I1=1.057 Amp

Area Of Cross Section Of Primary Conductor:

a1=I1/(current density of primary conductor)
a1=1.057/2.3=0.459 mm2

Current In Secondary Winding:

I2=VA/V2=200/30
I2=6.67A

Turns Of Secondary Winding:

T2=V2 x Te x 1.05
T2=30 x 3.5 x 1.05=110 turns

Area Of Cross Section Of Secondary Conductor:

a2=6.67/3.0
a2=2.223 mm2
Window Space Req For Primary Winding=T1 x a1/space factor
Taking Round Conductor,Diameter of Bare Conductor=(a1 x 4/pi)^1/2
=(0.459x4/pi)^1/2
=0.764 mm
We selected diameter=0.711;SWG=22
Diameter of insulated conductor=0.055+0.711
=0.766 mm
Assume Space Factor=0.8x(0.711/0.766)^2
=0.689
Window Space Req For Primary Winding=770 x 0.459/0.689
=512.96 mm2
Window Space Req For Secondary Winding=T1xa1/space factor
Diameter Of Bare Conductor =(a2 x 4/pi)^1/2
=(2.223x4/pi)^1/2
=1.682 mm
We Selected diameter=1.63mm ; SWG=16
Diameter Of Insulated Conductor=d1=1.63+0.07=1.7mm
Assume Space Factor=0.8x(1.63/1.7)^2=0.735
Window Space Req For Primary Winding=110 x 2.223/0.735
=332.69 mm2

Stamping Size:
Width Of Central Limb=37.815 mm=1.5 inch
A=1.1/2” B=4.1/2” C=3.3/4” D=3/4” E=3/4”

Hw = C-2E
=95.25mm-2(19.05mm)
=57.15mm
Ww = B-A-2D/2
Ww=114.3-38.1-2(19.05)/2
Ww=19.05mm
Area Of Window Available=Aw=Ww x Hw
=19.05mm x 57.15mm
=1088.7075 mm2
Window Space Required=1.2(512.96 x 332.69)=1014.78 mm

Hardware Design Of Transformer:

Front View:

Top View: