Transformers Used In Electronics is the main component of a switching power supply. There are many topologies for switching power supplies. For example, in a half-bridge power conversion circuit, two switching transistors take turns generating a 100kHz high-frequency pulse wave, which is then converted to output alternating current by a high-frequency transformer. The turn ratio of each high-frequency transformer winding determines the output voltage. A typical half-bridge transformer circuit in the most conspicuous are three high-frequency transformers, the main transformer, transformer, and auxiliary transformer (backup transformer), each transformer in the national regulations has their measures, such as the main transformer, as long as the power supply is more than 200W, the core diameter (level) shall not be less than 35mm. while the auxiliary transformer, when the power supply power is not more than 300W, its an iron core diameter of 16mm is sufficient.
High Frequency Transformer Design Principles
1. leakage inductance, in the design of Transformers Used In Electronics, transformer leakage is due to the primary coil and secondary coil, between the magnetic flux is not fully coupled and caused by the coil produced by the magnetic lines of force not be passed through the secondary coil, thus generating leakage inductance known as leakage inductance; designer, the wider the winding window, the smaller the number of laps, the smaller the number of layers of stacking, leakage inductance will be the more reduced, or will be stacked on top of each other with the primary and secondary to do offsetting to Reduce the generation of leakage inductance, this way called sandwich winding method.
2. Distributed capacitance, transformer winding turns, in the same winding between the upper and lower layers, or between different windings, windings and shielding layer formed between the capacitance known as the distributed capacitance; designers, usually placed in the primary winding in the innermost layer, so that the transformer can make the transformer primary winding each turn with the shortest length of the line, but also effectively reduces the primary winding of its own distributed capacitance, but the sandwich method of winding the parasitic capacitance increases, efficiency decreases, so this is the design of the primary and secondary winding method. Efficiency is reduced, so this is also what the designer needs to consider.
3. The switching power supply in the high-frequency transformer transmission is a high-frequency pulse square wave signal. In the transmission of the transient process, leakage inductance and distributed capacitance will cause inrush current and spike voltage, oscillating at the top, resulting in increased losses, which is why the design will require a low leakage inductance of the main reason, on the contrary, there are designers use leakage inductance to do the detection, because of the different designers, there will be different needs and design methods.
4. Insulation layer tape, between the primary and secondary windings usually need to add (2-3) layers of insulation tape, which can reduce the capacitance of the primary and secondary windings between the distribution capacitance, but also increase the strength of the insulation between the primary and secondary, to ensure that the insulation voltage requirements. The same often in the 1000V AC tape for 1-2 layers, 3000V AC tape will be 2-3 layers.
5. The shielding process, to be more effective in solving the problem of transformer interference, between the windings or the core of the outermost layer of conductive copper foil, must pay attention to the use of conductive copper foil between the windings is also grounded, it will increase the generation of thermal resistance, the generally conductive copper foil will be in the core or the outermost layer of the wire package to do grounding. Or you can add insulation tape to the outermost layer of the core to increase the shielding effect.
6. Insulation and voltage, in the design of high-frequency transformer is the key. When the conditions of pressure resistance are harsh, or the wireframe design safety distance is not enough, you can improve the pressure resistance specification of the material, or the use of retaining wall, tape, and casing, including immersion and other processes to increase the primary and secondary pressure resistance or safety distance between, or the use of casing to ensure that the tin plating or the safety distance between the wire package to be a common way.
What is the effect in a high frequency transformer if the inductance is out of the given range?
A high-frequency transformer is an electronic device used to transform voltage and current, usually used in wireless communications, power conversion, and electronic devices. In high frequency transformers, the selection and control of inductance is very important because it directly affects the performance and stability of the transformer. If the inductance exceeds a given range, the following effects will occur:
1. Core saturation: In high-frequency transformers, iron cores or magnetic materials are usually used to increase the inductance. When the inductance exceeds a certain range, the iron core may saturate. Core saturation leads to saturation of the magnetic flux density, which in turn leads to instability and distortion of the inductance. This may cause output voltage instability and harmonic distortion.
2. Increased Losses: Both the core and the coils inside the inductor produce some losses, usually in the form of copper losses and iron losses. When the inductance is too high, the current inside the coil becomes higher, resulting in more copper losses. Also, saturation of the iron core leads to an increase in iron losses. This will make the high frequency transformer less efficient.
3. Heat Problems: Increased losses can also cause the transformer to heat up more. If not properly cooled or not enough heat is dissipated, this can lead to an increase in temperature, which ultimately affects the life and reliability of the HF transformer.
4. Difficulty in adjustment: In high frequency applications, accurate inductance values are often necessary to ensure that the transformer will operate within design specifications. If the inductance value exceeds a given range, adjusting it will be more difficult and may require a redesign of the transformer.
5. Harmonic issues: The harmonic performance of high frequency transformers is important for some applications, such as wireless communication systems. Inappropriate selection of inductance values may lead to harmonic distortions that can affect communication quality.
To avoid these problems, the choice of inductance value needs to be carefully considered when designing a high frequency transformer and to ensure that it is within the design limits. Usually, the choice of inductance value is influenced by factors such as design requirements, operating frequency, input voltage and output voltage. In actual design, circuit simulation and experimental verification are usually required to ensure that the choice of inductance value is appropriate for performance and stability.
Application of new core structure in electronic transformers
1. Lap wound cores
Lap type of coiled core was first used in an amorphous alloy distribution transformer. It has the advantages of a coiled core, the excitation current is small, it has low no-load loss, and can be opened to load and unload the coil, eliminating the shortcomings of the general coiled core, do not need to use a special winding machine to wind the coil, production efficiency, coil problems are also easy to replace and repair. The thickness of the existing 3% oriented silicon steel has been reduced to 0.23mm and 0.27mm, and it is easier to manufacture lap wound cores with them than amorphous alloys. Therefore, lap wound cores may be used for more than 500VA silicon steel power transformers, especially large-capacity rectifier power supply and non-stop power supply in the silicon steel power transformer.
2. Three-dimensional triangular magnetic core
The three-dimensional arrangement of a triangular three-phase magnetic core is now popular in China. The earliest appearance of a three-dimensional triangular magnetic core can be traced back to the 1930s, but, because the core requires special shear processing, the coil needs a special winding machine winding, and failed to promote the application. Now you can use a computer to control the core shear processing, there has been a special winding machine winding. Domestic 5-6 enterprises in the application of three-dimensional triangular core transformer patents. The three-dimensional arrangement of the triangular three-phase magnetic core compared with the plane layout of the three-pillar three-phase magnetic core, magnetic flux distribution is uniform, there will be no local saturation, and the symmetry of the excitation current and magnetic flux is good. The problem is that it is quite difficult to form the cross-section of each column close to a circle, the average turn length of the winding increases, and the load loss increases. It can be used for large transformers above 30kVA.
3. Orthogonal core
Rotate half of the C-type core by 90°, and then join them together to form a quadrature core. The inductance of the quadrature core can be controlled by a DC control winding. Japan's Sony has made this core with soft magnetic ferrite, called SX-shaped core, and has been used in a variety of TV switching power supplies, as a drive transformer, controlling its inductance, so that the circuit appears to be voltage resonance or current resonance and to achieve soft switching conditions. Tohoku University and Tohoku Electric Power Company have made this core from silicon steel for use in power compensators and phase shifters to control active and reactive power in power systems. Compared with the thyristor power compensator and phase shifter, it has less high harmonics, less electromagnetic interference, and a simple control circuit.
4. Magnetic liquid core
Some people have envisaged, with injection molding machine processing transformer core, can avoid silicon steel core punching, heat treatment, stacking, assembly, and other procedures. Now developed magnetic liquid core can achieve this vision, made of engineering plastics core-shell, the middle of the injection of magnetic liquid, the surface, and then sealed with a magnetic sheet. In this way, mass production of small and medium-sized power transformers can significantly improve the processing efficiency, so that the cost reduction, compared with the stacked silicon steel core has obvious advantages.
Electronic transformers play an important role in power supply technology. Power technology requires electronic transformers can adapt to external conditions, reduce electromagnetic interference; complete power transfer, voltage conversion, insulation isolation and ripple suppression, and other functions; improve efficiency, and reduce costs. New soft magnetic materials and new core structures in the application of electronic transformers, not only promote the development of electronic transformers but also promote the development of power supply technology.
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Q: What are the main functions of the power transformer?
A: The main functions of a power transformer include: step-down, step-up, isolation signal, filtering and voltage stabilization, etc.
Q: Why do I need to use a power transformer?
A: The power transformer is a key component to convert alternating current into the direct current required by the equipment. The device requires a direct current to function properly. By using a power transformer, we can convert the alternating current provided by the grid into the direct current we need.
Q: What are the advantages of Transformers Used In Electronics?
A: High-frequency transformers have the advantages of high efficiency, small size, and lightweight. Among them, because it works in the high-frequency range, the high-frequency transformer can greatly reduce the loss in use, improve the efficiency of the use of components, and also reduce the volume and weight of components, to achieve a more compact and lightweight design, which is more suitable for practical application scenarios.
Q: What are the faults of high-frequency transformers?
A: The faults of high-frequency transformers mainly include open circuit faults, short circuit faults, and winding faults. Among them, the open circuit fault refers to the loosening or disconnection of some copper wires and iron cores inside the transformer, resulting in the failure of the circuit to be conducted, which is manifested as zero output signal or large voltage fluctuation; short circuit fault refers to the short circuit between some copper wires or iron cores inside the transformer and other parts, resulting in the direct conduction of the circuit, which is manifested as excessive output signal or voltage surge; winding fault refers to the internal tearing or damage to the electromagnetic coil winding, resulting in poor circuit conduction or distortion of the output signal.
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