Transformer Design
The requirements are as follow.
Input Voltage ¿ 24 V (20 V −26 V )
Output Voltage ¿ 3.7 V
Output current ¿7 A
Frequency ¿ 100 kHz
Efficiency ¿ 0.98
Regulation ¿ 0.5
Flux Density ¿ 0.1 T
Dmax = 0.365
6.62
Skin depth (₰) =
√f
=0.0209 cm
Wire diameter = 2₰
= 0.0418cm
πD2
Bare wire area ( AW ) =
4
= 0.00137 cm2
Hence appropriate AWG will be #26.
Output power ( P0 ) = I 0 (V 0 +V d )
= 7(3.7 +0.9)
= 32.2 w
The apparent output power (due to the interruption of the current) Pt = P0 (
√ 2 + √ 2)
η
=32.2(
√ 2 + √2)
0.98
=92w
K e =0.145 × K f 2 × f 2 × Bm 2 ×10−4
¿23200 ( K f =4 for square waves )
Pt
K g=
2× α × K e
=0.003966 cm5
So based on those values we decided to use the core mentioned above.
V P ( min) ×10 4
N P=
f × B AC × AC × K f
20× 104
=
100,000× 0.1× 0.24 × 4
¿ 20.833
≈ 21
Pt ×10 4
J=
f × B AC × A P × K U × K f
A
¿ 276.4423
cm2
P0
I ¿=
η ×V 0
32.2
= 0.98 ×28
= 1.173 A
I ¿ √ D max
A℘ =
J
= 0.00256 cm2
A℘
snp=
¿ 26
= 2.003 (use 2 sets of windings∈the primary core)
μΩ μΩ
new (for primary)= ÷s
cm cm np
= 1345/2
= 672.5
μΩ
Primary winding resistance (R P) = MLT ×21 × ×10−6
cm
= 0.04805 Ω
N P× V s α
Ns= (1+ )
V P (min) 100
= 4.855 (use 5 windings)
I o √ D max
AWs =
J
= 0.007986 cm2
A Ws
sns=
¿ 26
= 6.23 (use 6 sets of windings ∈the secondary core)
μΩ μΩ
new ( for secondary )= ÷s
cm cm ns
= 1345/6
= 224
μΩ
Secondary winding resistance ( RS )= MLT ×5 × ×10−6
cm
= 0.004783 Ω