Methodology For Calculating Low Power Supply Transformers

28/10/2020 4. Methodology for calculating low power supply transformers.
4. Methodology for calculating low power supply transformers.

This section describes the methodology for calculating low-power rectifier transformers (up to 1000 W at a network frequency of 50 Hz and
up to 2500 W at a network frequency of 400 Hz) with a secondary winding voltage of no more than 1000 V.
The data for calculating the transformer are:
Supply current frequency;
Rated voltages of primary and secondary windings;
Rated currents of secondary windings;
Typical power of the transformer.
The calculation is carried out in the following order:
4.1. For a given value of the typical power P from Table 1, we find the approximate values of the magnetic induction B, current density
type
, the filling factor of the winding with copper k , the filling factor of the section of the magnetic circuit with steel k and the efficiency
m st
(efficiency) .
Table 1 - Approximate values of B, ,k and .

m
Frequency Magnetic Steel k Typical transformer power P ,W

st type
f, Hz circuit grade
configuration and
thickness, 15-50 50- 150- 300- 1000-
mm 150 300 1000 2500
50 Armor E-42 0.94 B, t 1.3 1.3- 1.35 1.35- -

(lamellar) 0.35 1.35 1.2
,a/ 5-3.8 3.8- 1.9- 1.3- -

2 1.9 1.3 1.1
mm
k 0.22-0.28 0.28- 0.34- 0.36- -

m
0.34 0.36 0.38
https://studfile.net/preview/2123561/page:3/ 1/11
0.5-0.8 0.8- 0.9- 0.93- -

0.9 0.93 0.95
400 Armor E-320 0.85 B, t 1.6 1.6- 1.45- 1.2- 0.95-

(tape) 0.15 1.45 1.20 0.95 0.8
,a/ 6-4.5 4.5- 3.5- 2.5- 1.5-

2 3.5 2.5 1.5 1.2
mm
k 0.21-0.25 0.25- 0.28- 0.30- 0.37-

m
0.28 0.30 0.37 0.38
0.87 0.87- 0.94- 0.96- 0.97

0.94 0.96 0.97
4.2. Determine the value of the product of the core section by the section of the magnetic circuit window using the formula:
where P is the typical power of the transformer;

type
- efficiency factor;
f - power supply frequency;
B is the value of the magnetic induction;
k is the filling factor of the section of the magnetic circuit with steel;
st
k - coefficient of filling of the winding with copper.

m
3. By the value of S S and using the data of tables of Appendices 1 and 2,

article ok
choose the magnetic circuit.
For further calculation in these tables, you need the following data:
Active section of steel (S );

st
Core weight (G );
st
Heart rod width (a);
Window width (b);
Window height (h).
Figures 12 and 13 show the designs of armored plate and armored tape magnetic circuits.
Figure 12 - armor design Figure 13 - armor design
lamellar magnetic circuit. tape magnetic circuit
3. By the value of the magnetic induction B and according to table 2,

we determine the total
losses in steel by the formula:
where P - total losses in steel;

st
p - specific losses in steel (found from table 2);

st
G is the weight of the core.

st
Table 2 - Specific losses in steel and specific magnetizing power.
Frequency Steel Magnetic induction B, T

Hz grade
and
thickness, 0.8 0.9 1.0 1.1 1,2 1.3 1.4 1.5 1.6
mm.
50 E-42 p , 0.90 1.15 1.47 1.85 2.4 3.2 4.5 - -

st
0.35
W/
kg
qst, five 7.5 ten fifteen 22.5 35 65 - -

wa /
kg
400 E-320 p , 4.25 6,3 8.0 ten 12 14.2 16.5 20 24

st
0.15
W/
kg
qst, 22 36 48 68 90 118 114 180 220

wa /
kg
3. We find the active component of the no-load current by the formula:
where I is the active component of the no-load current;

oa
P - total losses in steel;

st
U - voltage of the primary winding.

1
4 .6. According to the magnitude of the magnetic induction Bi and according to the data in Table 2, we determine the total
magnetizing power of the core by the formula:
where Q is the total magnetizing power of the core;

st
q - specific magnetizing power of the core (found from table 2);

st
G is the weight of the core.

st
4.7. We find the reactive component of the no-load current by the formula:
where I is the reactive component of the no-load current;

op
Q is the total magnetizing power of the core;

st
U - voltage of the primary winding.

1
4 .8. We find the no-load current by the formula:
where I - no-load current;

0
I - active component of no-load current;

oa
I - reactive component of no-load current.

op
9. We find the relative value of the no-load current by the formula:
where I is the relative value of the no-load current;

0%
I - no-load current;
0
I - current in the primary winding.

1
If the value of I at a frequency of f = 50 Hz lies in the range of 30 50%, at a frequency of f = 400 Hz - in the range of 5 15%, then the
0%
choice of the magnetic circuit at this stage of the calculation can be considered complete. If I exceeds the upper limits indicated above,
0%
then the induction in the core should be reduced; at I less than the lower aisles, the induction should be increased.
0%
4 .10. Determine the number of turns in the windings by the formulas:
where w ,w - the number of turns in the primary and secondary windings, respectively;
1 2
U %, U2% - relative voltage drops in the windings (found according to table 3).
1
Table 3 - Relative voltage drops in the windings.
Frequency, Typical power P ,W

type
Hz
15 50 50 150 150 300 1000 2500

300 1000
50 U % 15 5 5 4 4 3 3 1 -
1
U % 20 10 10 8 8 6 6 2 -
2
400 U % 8 4 4 1.5 1.5 1 1 0.5 0.5

1
U % 10 5 5 2 2 1.2 1.2 0.5 0.5

2
4 .11. We find the cross-section of the wires of the windings by the formula:
where S is the section of the winding wire;

pr
I is the winding current;
- current density in the winding (determined from table 1).
4 .12. We select standard cross-sections and diameters of wires according to the data of Appendix 3, after which we clarify the
actual current density using the formula:
where S is the section of the winding wire;

pr
I is the winding current;
- current density in the winding (determined from table 1).
4 .13. We find the permissible axial length of the winding by the formula:
where h is the axial length of the winding;

d
h is the height of the magnetic circuit window.
4 .14. We determine the number of turns in one layer and the number of layers of each winding according to the
formulas:
where w is the number of turns in one layer;

c
h - axial length of the winding;

d
k - stacking coefficient, approximately equal to 1.07 1.15

y
(depending on the wire diameter).
d - the diameter of the insulated wire;

from
N is the number of layers in the winding;
w is the number of turns in the winding.
15. Choosing interlayer and interwinding insulation.
It is recommended to choose as interlayer insulation:
for wires with a diameter less than 0.1 mm - capacitor paper 0.01 mm thick,
for wires with a diameter of 0.1 0.5 mm - telephone paper 0.05 mm thick,
for wires with a diameter of more than 0.5 mm - cable paper 0.12 mm thick.
As interwinding insulation at voltages up to 1000 V, you can use various brands of insulating paper, wound in several layers. The total
thickness of this insulation can be taken equal to 0.2 0.3 mm.
4 .16. We find the radial size of each winding using the formula:
where is the thickness of the interlayer insulation;

from
n is the number of the winding.
4 .17. We find the radial size of the coil, that is, its thickness, according to the formula:
where is the gap between the inner part of the frame (sleeve) and the core ( = 0.5 mm.).
z z
- frame thickness ( 1 2 mm.)

к к
- radial dimensions of each winding;

i
- thickness of interwinding insulation ( 0.2 0.3 mm; 0.2 0.3 mm. -

1i 1i 1n
the thickness of the upper insulation layer of the coil);
n is the number of windings.
18. Check the gap between the coil and the core with - . The coil is normally placed in the core window if c - 2 4 mm. depending
on the power of the transformer. If the resulting size is less than 2 mm, then either increase the induction or select wires of smaller
diameters.
18. Determine the average length of the turns of each winding by the formula:
where a ,b - internal dimensions of the coil (see Figure 8);

to to
r - upper radius of the previous winding
(r = /2; r = + + /2; r = + + + + /2...i.t.d).

1 1 2 1 12 2 3 1 12 2 23 3
Figure 8 - Placement of the coil on the magnetic circuit.
4.20. Determine the weight of the copper of each winding by the formula:
g dew is the total number of turns in the winding;
l - the average length of the turn;

cf. in
g - weight of 1 meter of insulated wire (see Appendix 3).

pr
4 .21. We find the loss in copper of each winding by the formula:
where - temperature coefficient (found from table 4);
- current density in the winding;
G - the weight of the copper of each winding.

m
Table 4 - Temperature coefficient values.
Wire 20 90 105 120 130 155 180 200

temperature, С
Temperature 2.26 2.52 2.65 2.76 2.84 3.02 3.23 3.38

coefficient [ ]
4 .22. Let's find the total losses in copper of the coil by the formula:
where P - losses in copper of the i- th winding.

mi
4.
5. 4 .23. Determine the cooling surface of the coil by the formula:
where h is the axial length of the winding;

d
- the gap between the inner part of the frame (sleeve) and the core ( = 0.5 mm.);
h h
- frame thickness ( 1 2 mm.);

к к
- the radial size of the coil;
a - the internal size of the coil;

to
4 .24. Determine the specific surface load of the coil by the formula:
4 .25. The curves in Figures 9 and 10 (depending on the frequency of the network current) determine the average
temperature of the coil overheating .
Figure 9 - Curves of the dependence of the overheating temperature on the specific load
windings of armored transformers with lamellar cores
at a mains frequency of 50 Hz.
Figure 10 - Curves of the dependence of the overheating temperature on the specific load
armored transformer windings with tape cores
at a mains frequency of 400 Hz.
Adding to it the specified ambient temperature at which

the transformer will operate, we obtain the operating
temperature of the winding wires. This temperature
should not exceed +100 С for PEL wires and +105
С for PEV wires.
4 .26. Let's determine the resistance of each winding by

the formula:
4 .27. Determine the actual voltage drops in each

winding by the formula:
If there is a significant discrepancy between the values

of U and those previously adopted, the number of
turns of the
windings
should be
corrected.
This concludes the calculation of the transformer.
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Methodology For Calculating Low Power Supply Transformers

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28/10/2020 4. Methodology for calculating low power supply transformers.

4. Methodology for calculating low power supply transformers.

The data for calculating the transformer are:

Supply current frequency;

Rated voltages of primary and secondary windings;

Rated currents of secondary windings;

Typical power of the transformer.

The calculation is carried out in the following order:

Table 1 - Approximate values of B, ,k and .

Frequency Magnetic Steel k Typical transformer power P ,W

50 Armor E-42 0.94 B, t 1.3 1.3- 1.35 1.35- -

,a/ 5-3.8 3.8- 1.9- 1.3- -

k 0.22-0.28 0.28- 0.34- 0.36- -

0.5-0.8 0.8- 0.9- 0.93- -

400 Armor E-320 0.85 B, t 1.6 1.6- 1.45- 1.2- 0.95-

,a/ 6-4.5 4.5- 3.5- 2.5- 1.5-

k 0.21-0.25 0.25- 0.28- 0.30- 0.37-

0.87 0.87- 0.94- 0.96- 0.97

where P is the typical power of the transformer;

f - power supply frequency;

B is the value of the magnetic induction;

k - coefficient of filling of the winding with copper.

3. By the value of S S and using the data of tables of Appendices 1 and 2,

choose the magnetic circuit.

Active section of steel (S );

Heart rod width (a);

Window width (b);

Window height (h).

Figure 12 - armor design Figure 13 - armor design

lamellar magnetic circuit. tape magnetic circuit

3. By the value of the magnetic induction B and according to table 2,

losses in steel by the formula:

where P - total losses in steel;

p - specific losses in steel (found from table 2);

G is the weight of the core.

Table 2 - Specific losses in steel and specific magnetizing power.

Frequency Steel Magnetic induction B, T

50 E-42 p , 0.90 1.15 1.47 1.85 2.4 3.2 4.5 - -

qst, five 7.5 ten fifteen 22.5 35 65 - -

400 E-320 p , 4.25 6,3 8.0 ten 12 14.2 16.5 20 24

qst, 22 36 48 68 90 118 114 180 220

3. We find the active component of the no-load current by the formula:

where I is the active component of the no-load current;

P - total losses in steel;

U - voltage of the primary winding.

where Q is the total magnetizing power of the core;

q - specific magnetizing power of the core (found from table 2);

G is the weight of the core.

where I is the reactive component of the no-load current;

Q is the total magnetizing power of the core;

U - voltage of the primary winding.

4 .8. We find the no-load current by the formula:

where I - no-load current;

I - active component of no-load current;

I - reactive component of no-load current.

9. We find the relative value of the no-load current by the formula:

where I is the relative value of the no-load current;

I - current in the primary winding.

4 .10. Determine the number of turns in the windings by the formulas:

Table 3 - Relative voltage drops in the windings.

Frequency, Typical power P ,W

15 50 50 150 150 300 1000 2500

400 U % 8 4 4 1.5 1.5 1 1 0.5 0.5