Tell me, how did you learn transformer design?

okhxyyo

Tell me, how did you learn transformer design? [Copy link]

 

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Hello everyone~~ I recently chatted with people and found that many friends want to learn about transformers. So, today we are going to talk about the question of "how to learn transformer design". Welcome everyone to join the discussion and share your experience and experience in the process of learning transformers~~

AI assistants are quite convenient. For example, they can help me sort out my thoughts. I asked Wenxin Yiyan to give me a suggestion for the learning route of "transformer design". I put it here to start my discussion:

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For electronic engineers to learn transformer design knowledge, the following is a specific list of learning contents, which covers all aspects from basic knowledge to advanced applications:

1. Basic knowledge

1. Fundamentals of Electromagnetism
   • Principle of electromagnetic induction
   • Faraday's law of electromagnetic induction
   • Lenz's law
   • Basic properties and calculations of magnetic fields
2. Circuit Theory
   • Basic analysis methods of DC circuits and AC circuits
   • Applications of Kirchhoff's Laws and Ohm's Law
   • Impedance, Phase Angle and Power Factor in AC Circuits
   • Resonant circuit and filter design principles
3. Electronic devices and materials
   • Basic characteristics and applications of resistors, capacitors and inductors
   • Working principle of semiconductor devices (diodes, transistors)
   • Characteristics and selection of transformer core materials (such as silicon steel sheets and amorphous alloys)
   • Conductivity and insulation requirements of winding materials (such as copper and aluminum)

2. Basic principles and design of transformers

1. Working Principle of Transformer
   • Application of electromagnetic induction in transformer
   • Relationship between voltage ratio and turns ratio
   • Current and power transfer characteristics
2. Transformer structure and design
   • The structure and type of the core (such as laminated core, wound core)
   • Layout and connection of windings (e.g. series, parallel, star, triangle)
   • Insulation system design and material selection
   • Design and selection of cooling system (such as natural cooling, air cooling, water cooling)
3. Transformer performance parameters and tests
   • Definition and calculation of rated capacity, rated voltage and rated current
   • Test methods for performance parameters such as voltage change rate, efficiency, and loss
   • Insulation resistance, leakage current, withstand voltage test and other safety performance testing

3. Transformer Design Practice

1. Design process and methods
   • Demand analysis: determine the purpose, capacity, voltage level, etc. of the transformer
   • Solution formulation: selection of core material, winding material, structure type, etc.
   • Detailed design: calculation of parameters such as number of turns, wire diameter, insulation thickness, etc.
   • Manufacturing and assembly: Develop manufacturing process, assembly requirements and inspection standards
2. Design Software and Tools
   • Learn to use electromagnetic simulation software (such as ANSYS, Maxwell, etc.) to simulate transformer design
   • Master CAD design software (such as AutoCAD, SolidWorks, etc.) to carry out transformer structure design
   • Learn to use test instruments and equipment (such as oscilloscopes, power analyzers, insulation resistance testers, etc.) to test transformer performance
3. Practical skills
   • Process Control and Quality Inspection in Transformer Manufacturing
   • Troubleshooting and troubleshooting methods during transformer commissioning and operation
   • Basic knowledge and skills of transformer maintenance and care

4. Advanced and Special Transformer Design

1. Special type transformer
   • Working Principle and Design Method of Autotransformer
   • Design and application of electronic transformers (such as transformers in switching power supplies)
   • Working principle and performance parameters of transformers (such as current transformers and voltage transformers)
2. Optimization and Improvement
   • Methods for reducing transformer losses and improving efficiency
   • Design strategy for heat dissipation and temperature rise control of transformer
   • Improvement of transformer insulation system and reliability enhancement
3. New technology applications
   • Application research of new core materials (such as nanocrystalline alloys and amorphous alloys)
   • Innovations in winding technology (such as copper foil winding, flat wire winding) and their advantages
   • Application and development trend of smart transformer and Internet of Things technology

5. Continuous Learning and Development

1. Industry standards and regulations
   • Familiar with the standards and regulatory requirements of the transformer industry at home and abroad
   • Understand the certification process and requirements of transformer products (such as CE certification, UL certification, etc.)
2. Academic Exchange and Training
   • Participate in academic conferences, seminars and other activities to learn about the latest research results and technical trends in the transformer field
   • Participate in training courses and seminars to improve your professional skills and knowledge

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Share some transformer information:

Design and calculation of transformer for low power high frequency switching power supply

Transformer Engineering: Design and Practice English Edition

Electronic Transformers Brochure

Transformer design 110 pages PPT full version

Switching power supply transformer design

Switching power supply transformer design example (detailed formula)

Ways to reduce the loss of switching power supply transformer

Example calculation of output filter capacitor of flyback power supply

Transformer good information

hawksabre

I learned transformer design based on the topology of the power supply. It took me six or seven years to finally learn the transformer design of various topology power supplies. The design of magnetic components is the main part of hardware design. Low-frequency transformers, medium-frequency transformers, audio transformers, inductors, high-frequency transformers, drive transformers, DC motors, AC motors (synchronous motors, asynchronous motors), it can be said that the design of transformers runs through the beginning and end of the power electronics discipline.

振动试验仪器

The amplifiers on the vibration tables I repair usually have burnt-out tubes.

I have also encountered bad inductors, but they are very rare.

I disassembled the power inductor. The E-type inductor can be disassembled. The inductance of the air-core coil measured with an LCR meter is generally micro-H. Adding an iron core to measure the inductance of the coil can reach mH.

By adding a magnetic resistance sheet between the magnetic cores, the inductance of the coil will be significantly reduced. Most of the inductors actually used have magnetic resistance added to reduce the inductance of the coil to prevent magnetic saturation when the inductor is used.

UUC

Our industry and positions have more applications, but we have never studied the design aspect. We have not read the professional standards and specifications in detail.

xutong

Without such a system, we can only get the inductance and turns ratio.

振动试验仪器

The inductance of a power mutual inductor is larger than that of a single power inductor. The magnetic resistance added between the magnetic cores of the mutual inductor is small, that is, the gap between the magnetic cores is small, and the reduction in the inductance of the coil is small.

The gap between the magnetic cores of a single inductor is generally large, and the inductance of the coil will be greatly reduced.

okhxyyo

hawksabre posted on 2024-10-19 13:58 I learned transformer design based on the topology of the power supply. It took me six or seven years to finally learn all kinds of topology power supplies...

This method is interesting! I learned a lot~

okhxyyo

Vibration Test Instrument Published on 2024-10-20 01:05 The amplifiers I repair on the vibration table are usually mostly burnt out. I have also encountered broken inductors, but it is very rare. I disassembled the power inductor, E ...

Thank you for sharing your experience! This kind of practical problem sharing is really helpful to everyone.

fxyc87

In fact, I have always wondered whether transformers can be made into standard parts like resistors and capacitors, like ordinary inductors.

For example, I have a 20W transformer with 3 windings, main winding, feedback, and power supply. I have a standard part and a specification, and all manufacturers follow this specification.

Otherwise, everyone has to order transformers from the factory, which is troublesome with small quantities.

金周路秀才

Transformers are basically used in the RF field for impedance transformation, focusing only on application frequency and turns ratio.

okhxyyo

fxyc87 posted on 2024-10-22 08:49 In fact, I have always wondered if transformers can be made into standard parts like resistors and capacitors, like ordinary inductors. For example, if I make a 20W transformer with 3 windings...

This idea sounds great~~ I just don't know if any manufacturers or organizations have been promoting it for so long, or if not, what's the reason? I'll find out when I have time.

maychang

fxyc87 posted on 2024-10-22 08:49 In fact, I have always wondered if transformers can be made into standard parts like resistors and capacitors, like ordinary inductors. For example, if I make a 20W transformer with 3 windings...

If transformers were made into standardized components like resistors and capacitors, manufacturers would have done so long ago if it were possible.

It is not that manufacturers have never done this before. I have seen standardized flyback switching power supply transformers produced by American manufacturers, but they have not been promoted. I think the production volume is too small and it is not profitable, so the manufacturers stopped after a brief trial.

soso

hawksabre posted on 2024-10-19 13:58 I learned transformer design based on the topology of the power supply. It took me six or seven years to finally learn all kinds of topology power supplies...

Did you learn power topology by yourself? Please share your experience. We would also like to organize forum friends to join us.

木犯001号

fxyc87 posted on 2024-10-22 08:49 In fact, I have always wondered if transformers can be made into standard parts like resistors and capacitors, like ordinary inductors. For example, if I make a 20W transformer with 3 windings...

There must be enough interest to drive it

木犯001号

Winding the transformer, more experience in practice

他们逼我做卧底

hawksabre posted on 2024-10-19 13:58 I learned transformer design based on the topology of the power supply. It took me six or seven years to finally learn all kinds of topology power supplies...

This method is really good. Learned ~

他们逼我做卧底

Jin Zhoulu Xiucai published on 2024-10-22 09:10 Transformers are basically used in the RF field for impedance transformation, and only the application frequency and turns ratio are concerned

Can you also talk about how to determine the frequency and turns ratio in the application of radio frequency? ?

他们逼我做卧底

fxyc87 posted on 2024-10-22 08:49 In fact, I have always wondered if transformers can be made into standard parts like resistors and capacitors, like ordinary inductors. For example, if I make a 20W transformer with 3 windings...

This may not be easy to fix.