METHODS FOR DESIGNING AND MANUFACTURING TRANSFORMERS

摘要

Disclosed is an electrical transformer for improved transformer power capacity and efficiency designed by the application of disclosed design considerations. One embodiment design consideration is a method to configure power transformer windings wherein the minimum distance of the primary windings from the winding axis/core center is greater (the primary windings are more distal) from the winding axis than the minimum distance of the secondary windings, which are wound around the minimum interior core diameter. This design consideration is extended from single bobbin transformer designs to split bobbin designs, with the requisite distal increase of the primary windings (from the core axis) geometrically provided by an enlarged core bobbin center leg (axial) dimension beneath the primary winding window. Another disclosed design consideration is to fix the primary winding length relationship to the core weight for given transformer specifications in accordance with the disclosed unexpected experimental results and formula.

主权项

1. A method for designing a transformer comprising:
setting specifications for the transformer input voltage, output voltage, and power capacity, setting an initial primary winding length at a first length based on conventional transformer design criteria, estimating an initial secondary winding length by calculating the secondary length L to be the specified secondary voltage multiplied by said primary winding length divided by the specified primary voltage, determining minimum wire gauges for the primary and secondary windings necessary to meet said specified power capacity wherein the initial winding lengths and determined initial wire gauges form the initial primary and the initial secondary windings, winding the initial secondary winding around a selected secondary core segment, winding the initial primary winding around a selected primary core segment, testing the output voltage of the transformer to determine whether the output voltage meets the output voltage specification, modifying iteratively the secondary winding length and rewinding and retesting the output voltage until the output voltage meets the output voltage specification, testing the width of wound secondary winding to determine whether the secondary windings fill the selected secondary core segment, modifying iteratively the secondary winding gauge and rewinding and retesting the secondary windings until the secondary windings fill the selected secondary core segment, testing the width of wound primary winding to determine whether the primary windings fill the selected primary core segment, modifying iteratively the primary winding gauge and rewinding and retesting the primary windings until the primary windings fill the selected primary core segment.