- #1
How to Calculate Ferrite Transformer
- Thread starter NIKOLA TESLA Oficial
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Discussion Overview
The discussion revolves around the calculation and design of a ferrite transformer operating at 50 kHz. Participants explore various aspects of transformer design, including the number of turns, wire size, and current requirements, while considering different applications such as switching power supplies and communication transformers.
Discussion Character
- Exploratory
- Technical explanation
- Debate/contested
- Homework-related
- Mathematical reasoning
Main Points Raised
- Some participants emphasize that the design approach for a ferrite transformer depends on factors such as power level, signal type, bandwidth, cost constraints, and safety issues.
- One participant inquires about the meaning of "single source" in relation to the transformer design and asks for clarification on the intended switching topology and whether the project is a prototype or a product requiring certifications.
- Another participant mentions the basic EMF equations for transformers and suggests that while these equations provide foundational concepts, actual design involves more complex parameters.
- Concerns about wire size are raised, noting that it relates to cost, space limitations, and heat dissipation, particularly due to copper losses and skin effect at high frequencies.
- Current requirements are discussed in relation to the input/output power of the transformer, with a reference to the power equation P=V*I.
- Several participants share links to resources and suppliers that could assist in transformer design, indicating a collaborative effort to find useful tools and information.
Areas of Agreement / Disagreement
Participants generally agree that transformer design is complex and influenced by multiple factors, but there is no consensus on specific design methodologies or parameters, as various viewpoints and questions remain unresolved.
Contextual Notes
Limitations include the need for more specific information regarding the intended application and design constraints, as well as the complexity of transformer design that may not be fully captured by basic equations.
- #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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