Toroidal transformers: Winding, Design, Calculation
If you’re interested in producing a welding machine or a voltage stabilizer, then you definitely need to know what toroidal transformers are. But the most important thing is how they work and the subtleties they have in manufacturing. In addition, due to their design, such transformers are capable of giving more power compared to those which are wound on a W-shaped core. These devices are therefore ideal for powering very powerful equipment, such as low-frequency amplifiers.
So, you need to study the material before proceeding with the manufacture of the transformer. First, you need to determine the type of wire used. Second, you need to calculate the number of turns (it follows that you will know how many meters of wire you need). Third, you definitely need to choose a cross-section of the wire. The output current depends on this parameter, therefore, on the power of the toroidal transformer.
It is also necessary to consider that heating will occur with a small number of turns in the primary winding. A similar situation arises if the power of the consumers connected to the secondary winding exceeds the value that the transformer can give. The result of overheating is a reduction in reliability. In addition, overheating can even set the transformer on fire.
What will be required for the manufacturing toroidal transformer?
So, you’re starting to make a transformer. Tools and materials need to be acquired. Of course, even a sewing needle or matching needle may be required, but surely everyone has such accessories.
The steel from which toroidal transformers are made is the most important thing. You’re going to need a lot of transformer steel, it should be in the form of a torus. Furthermore, the wire is in varnish insulation, of course. Mandatory presence of PVA masking tape and glue. In addition, fabric-based electrical tape is needed to separate the windings. And a couple of pieces of wire to connect the ends of the windings. In addition, the wire must be used for silicone or rubber insulation.
Use of CRGO Steel for toroidal transformer
An accessory of this type seems really hard to get. Nonetheless, you will find useless voltage stabilizers in every house or shed, including at metal reception points. Whether this stabilizer works or burns out doesn’t matter to you! The toroidal transformers used in it are the main thing. They are the base of your design. Before this, though, the old winding made of aluminum wire must have been discarded. And then-core preparation with CRGO steel is being done. Note that the angles are right. You do not need this, since the varnish isolation which can be damaged.
And now a little on how the toroidal transformer calculation is performed. Of course, you can use simple programs, of which there are a lot. A ruler and calculator can be used to make a calculation. It will, of course, have an error, since it does not take into account many more factors that generally exist in nature. In the calculation, you should adhere to one rule-the the power of the secondary coil in the primary winding should not be greater than the same value.
The winding of Toroidal Transformer
It is very time-consuming for a phase like winding a toroidal transformer. Well, if the magnetic circuit can be disassembled, and assembled together after winding. But if that’s not possible then you can use some sort of spindle. You wind there on a certain amount of wire. Then, passing through the torus this spindle stack the windings turns. It can take a lot of time so it’s easier to buy a ready-made power supply if you’re not comfortable with your abilities.
Using a given example, the process is best represented. In general, the primary winding is powered by an alternating voltage network of 220 V. Suppose you need two secondary windings so that each output is 12 V. And in the primary winding you also use a 0.6 mm cross-section wire. The cross-sectional area will, therefore, be roughly 0.23 square meters. Mm But these are not all calculations, toroidal transformers need to adjust all parameters carefully. Once again, a bit of arithmetic-you has to divide 220 (V) by the number of secondary circuit voltages. Consequently, you get a coefficient of 3.9.
This means that the wire cross-section used in the secondary winding will be precisely 3.9 times greater than the primary cross-section. You need to use a simple formula to determine the number of turns for the primary winding multiply the coefficient “40” by the voltage (in the primary circuit it is 220 V), after which this amount is divided by the cross-sectional area of the magnetic circuit. It is worth noting that it’s precision and service life depends on how accurately the toroidal transformer measurement is performed. So it is easier to repeat every step of the calculation again.