- #1
How to Calculate Ferrite Transformer
- Thread starter NIKOLA TESLA Oficial
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SUMMARY
This discussion focuses on the design of a ferrite transformer operating at 50 kHz, specifically addressing the calculation of turns, wire size, and current. Key factors influencing the design include power level, signal type (such as switching power supplies), bandwidth, cost constraints, and safety requirements. Participants recommend utilizing resources like Fair-Rite and Wurth for design tools and materials, emphasizing the importance of understanding the specific application and topology of the transformer. The basic EMF equations for transformers are also highlighted as foundational knowledge for design considerations.
PREREQUISITES- Understanding of transformer design principles
- Familiarity with the basic EMF equations of transformers
- Knowledge of switching power supply topologies
- Awareness of safety and EMI certification requirements
- Research the design tools available at Fair-Rite for ferrite transformer calculations
- Explore Wurth's resources for switchmode power supply transformers
- Study the basic EMF equations and their application in transformer design
- Investigate safety and EMI considerations in power supply design
Electrical engineers, power supply designers, and hobbyists involved in transformer design and optimization will benefit from this discussion.
- #2
berkeman
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Welcome to the PF. 
There are some pretty general design methodologies, but the actual design approach will depend on several things:
Also, what is your background in electronics and math? That also will help us to guide you the best. Thanks.
There are some pretty general design methodologies, but the actual design approach will depend on several things:
- Power Level
- Signal type (switching power supply, communication transformer, etc)
- Bandwidth
- Cost constraints (does it need to be cheap in high volume?)
- Safety issues (does it need to be designed as a safety barrier for AC Mains applications like switching power supplies?)
Also, what is your background in electronics and math? That also will help us to guide you the best. Thanks.
- #3
NIKOLA TESLA Oficial
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2 Amp, 220 Volt Ferrite Transformer.berkeman said:Welcome to the PF.
There are some pretty general design methodologies, but the actual design approach will depend on several things:
If you can give us an idea for each of these initial questions/items, that will help us a lot to guide you to some good transformer design tutorials. If you want to design a transformer for a 50kHz off-line switching power supply, that is very different from designing a wideband communication transformer for 50kHz twisted pair communication...
- Power Level
- Signal type (switching power supply, communication transformer, etc)
- Bandwidth
- Cost constraints (does it need to be cheap in high volume?)
- Safety issues (does it need to be designed as a safety barrier for AC Mains applications like switching power supplies?)
Also, what is your background in electronics and math? That also will help us to guide you the best. Thanks.
AC Signal Type, Unswitched Output, Analog, single source at 50 KHz frequency
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- #4
NIKOLA TESLA Oficial
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Can anybody help me !? I just wanted to know how to correctly calculate a ferrite transformer, that's all!
- #5
Tom.G
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Try this site and click on the Design Tools of your choice. They are a major supplier of ferrite material and have been around for decades. They should be able to get you started.
https://www.fair-rite.com/
Cheers,
Tom
https://www.fair-rite.com/
Cheers,
Tom
- #6
NIKOLA TESLA Oficial
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Thanks Tom.G !Tom.G said:
- #7
berkeman
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That helps some, but there are still a few questions that would help to know the answers to.NIKOLA TESLA Oficial said:
I don't know what "single source" means. Does that mean that you will be generating a single output voltage rail with this offline switching power supply? Do you know what switching topology you are planning on using for this power supply? Will this be a one-off prototype, or do you intend to make this into a product with safety and EMI certifications?
And designing an offline switching power supply is more than just designing the transformer. Can you say more about this project and your background?
Here's a helpful overview of power supply design:
https://www.onsemi.com/pub/Collateral/SMPSRM-D.PDF
And Wurth is a very good supplier of switchmode power supply transformers. I've experienced excellent customer service with them, including some great help figuring out a conducted EMI problem that we were having with a recent Power Factor Corrected SMPS design...
https://www.we-online.com/web/en/pa...cts_pbcm/landing_pages/CustomTransformers.php
And this page at Wurth for new transformer design requests will help to give you an idea of the different things that you need to think about when designing a new SMPS transformer:
https://www.we-online.com/web/en/pa...gnetics/midcom_custom_design_enquiry_form.php
- #8
alan123hk
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NIKOLA TESLA Oficial said:
Transformer design and optimization is not easy, I also try to search for relevant information online from time to time.
I guess that the basic EMF equation of transformer can provide some useful basic concepts, although the actual design may involve more other parameters and may be a lot more complicated.
E1 = 4.44f N1 Φm
E2 = 4.44f N2 Φm
https://www.electricaleasy.com/2014/03/emf-equation-of-transformer.html
According to the equations :
Number of turns is related to the primary/secondary voltage and maximum magnetic flux
Wire size is obviously related to cost consideration, space limitations and heat dissipation since Copper Loss = I^2*I (skin effect should be considered at high frequencies...)
Current is obviously related to transformer Input/output power since P=V*I
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