HIGH FREQUENCY TRANSFORMER

DESIGNING & IMPLEMENTATION

WITH PERFORMANCE ANALYSIS
USING SIMULATION &
MATHEMATICAL MODEL
WHAT IS TRANSFORMER ?

Transformer is an electrical static device that transform energy. A transformer

consists of two electrically isolated coils and operates on Faraday's principal of
“mutual induction”, in which an EMF is induced in the transformers secondary
coil by the magnetic flux generated by the voltages and currents flowing in the
primary coil winding.
 APPLICATION OF FERRITE CORE
TRANSFORMER
• Now a days ferrite transformer are one of the most vital component in electrical
circuit as the can be operated at higher frequency .
• Ferrite transformer are relatively small.
• Ferrite transformer are also used in fly back transformer , microwave oven, auto
motive ignition coil etc.
• Ferrite transformer are used in SMPS( Switch Mode Power Supply ).
• Ferrite transformers are also used high frequency stabilization purposes.
 TRANSFORMER REQUIREMENT

Our aim was to design a transformer which will be used in high frequency stabilizer the design
had to be
• Compact and small.
• Operating frequency of 10 KHz.
• Primary voltage of rating of 80 volts to 300 volts.
• Secondary voltage rating of 300 volts.
• Power rating of 3000 watts.
• Performance Analysis using simulation software to check stability.
 DIFFERENCE BETWEEN FERRITE CORE TRANSFORMER
AND STEEL ORIENTED CORE TRANSFORMER ?

In high frequency applications like switch mode power supply ( SMPS ), Ferrite cores are used for
transformer whereas in low frequency applications like 50/60 Hz iron cores are used.
Ferrite core Transformer Steel oriented core transformer

Have low saturation flux density Have high saturation flux density

Saturates when used in low frequency such as 50/60 Saturates at higher frequency up to 60 Hz.
Hz.

Compact in size due to high frequencies. Bigger in size.

Low eddy current losses due to high resistivity, High Eddy current losses.

Smaller and lighter Bigger and bulkier

Fewer turns on primary and secondary More turns on primary and secondary

A number of small conductors are used rather then a Single or fewer conductor are used due to less skin
one large conductor to reduce the skin effect effect.
TYPES OF TRANSFORMERS
 HIGH FREQUENCY
FERRITE TRANSFORMER
LAMINATED CORE
TRANSFORMER
 DESIGN AND CALCULATIONS

The criteria of designing a ferrite core transformer is rather different from laminated core
transformer .
First of all the core selection criteria's differs from laminated cores as the laminated cores are not
capable of handling the frequencies above100Hz.
The selection of cores type, size and material depends upon power rating and the operating
frequency of the transformer .(In most cases for high frequency ferrite core are used).
We selected the EE type ferrite core according to our requirements
EE TYPE
CORE
 FERRITE CORE SELECTION PARAMETERS

• Select yoke area according to power rating using the table of the specific core manufacturer.
• Check the window area for clearance after calculating the winding area .
• Check for the specific frequency range .
• Check for the flux density( gauss/webber ).
 WINDING CALCULATIONS

•   relation of the transformer with the turn’s ratio to the voltage and current is given by
The

 
The following equation shows how the various design variables can be manipulated to achieve the
desired outputs.
 ACTUAL CALCULATION AND MEASUREMENTS OF
WINDING PARAMETERS

•  
For primary winding • Bmax = flux density of ferrite core
• Ac = Area cross section

• Npri = no of primary turns

• Vin = input voltage
• F = frequency
•Vin
  = 80 v
F = 10kHz
Bmax = 1600 Gauss
Ac = 6.8 cm2

=18.38 turns
 FOR SECONDARY WINDING
•As  we know

So

• Np = primary turns
• Ns = secondary turns
• Vp = primary voltage
• Vs = secondary voltage
•Np  = 18turns
Vp = 80v
Vs = 300 v

Ns = 68 turns

Measured parameters
Primary winding resistance = Rp = 0.2282 ohm

Primary winding inductance = XLp = 1.21mH

Secondary winding resistance = Rs = 0.1940 ohm

Secondary winding inductance = XLs =14.38mH
WINDING
 PRIMARY WINDING

• Primary winding consists of two coils with 18 turns each, connected in parallel.
• The material used for primary windings is copper wire with dimensions of 19 AWG.
• 3 conductors in parallel were used in winding so the current could easily handled.
• The coils are wound in same directions resulting in a high total flux.
• While the primary winding length is approximately 2.16m.
 SECONDARY WINDING

• Secondary winding of the transformer is composed of 68 turns of enameled copper wire .

• The conductive diameter of the wire is 21 AWG and its total length is 8.16m.
• While the primary winding length is approximately 2.16m.
 CORE OR IRON LOSSES

There are two types of core or iron losses in a Transformer

• Hysteresis Losses

• Eddy Current Losses

 HYSTERESIS LOSSES

• Each time the magnetic field is reversed, a small amount of energy is lost due to hysteresis
within the core.
• For a given core material, the transformer losses are proportional to the frequency, and is a
function of the peak flux density to which it is subjected.
We can find Hysteresis losses by the following formula.
Wh = ηB1.6maxf.v  watt
 ACTUAL CORE LOSE FOR PARTICULAR
FERRITE CORE
•   loss/kg = 1530.32 watts/kg
Watt
Weight of core = 530 gm
Hysteresis losses of core
Weight of yoke =
= 176grams
So the total loss of core is
Wh core= * 176 = 270 watts
Hysteresis losses in our transformer is 270 watts
 TO FIND HYSTERESIS LOSS

Formula
Wh = KfmBn

F = 10Khz
m= 1.50
K=1.698(10-4)
B=0.16 Webber
Wh= 1.698(10-4) * (1000)1.50 * (0.16)2.25

Wh= 1530.32 Watt loss/kg

 EDDY CURRENT LOSSES

• Eddy currents circulate within the core in a plane normal to the flux, and are responsible for
resistive heating of the core material.
• Ferromagnetic materials are good conductors, and a core made from such a material also
constitutes a single short-circuited turn throughout its entire length. 
We can find Eddy currents losses by the following formula. 
We = PB2max.f2t2   Watt
 COPPER LOSSES

• Current flowing through the windings causes resistive heating of the conductors.
• At higher frequencies, skin effect and proximity effect create additional winding resistance and
losses.
We can find Copper losses by the following formula. 
Total copper losses. = I12. R1+ I22R2 = I12. R 01+ I22R 02
 STRAY LOSSES

• Leakage inductance is by itself largely lossless, since energy supplied to its magnetic fields is
returned to the supply with the next half-cycle.
• However, any leakage flux that intercepts nearby conductive materials such as the transformer’s
support structure will give rise to eddy currents and be converted to heat.
• There are also radiative losses due to the oscillating magnetic field, but these are usually small
and negligible.
 DIELECTRIC LOSS

• In the solid insulation or transformer oil i.e. insulation material of the transformer, dielectric loss
occurs when the solid insulation get damaged or the oil gets deteriorated or its quality decreases
over the time.
• Hence, the overall efficiency of transformer may be affected due to this loss.
EQUIVALENT CIRCUIT
 EQUIVALENT CIRCUIT PARAMETERS

• Primary winding resistance = Rp = 0.2282 ohm

• Primary winding inductance = XLp = 1.21mH

• Secondary winding resistance = Rs = 0.1940 ohm

• Secondary winding inductance = XLs =14.38mH

 RESULTS AND ANALYSIS

After the designing and assembling of the Transformer we needed to check weather if the designed
unit was stable or not. To do so, we measured its impedance using the LCR meter. All readings
were taken after setting the LCR meter to a frequency of 10 KHz.
After gathering the relative data and noting it down. All this data was placed in a simulation
software using a proper model which helped in calculating and checking weather if the designed
transformer was stable or not.
Transfer function, bode plot, zeros and poles and other relative information was collected using the
simulation software 20 Sim
 WHAT IS 20SIM?

• 20-sim is a modeling and simulation program for mechatronic systems. With 20-sim you can
enter model graphically, similar to drawing an engineering scheme. With these models you can
simulate and analyze the behavior of multi-domain dynamic systems and create control systems.
You can even generate C-code and run this code on hardware for rapid prototyping and HIL-
simulation.
• 20-sim provides you with tools that allow you to create models very quickly and intuitively. You
can create models using equations, block diagrams, physical components and bond graphs.
Various tool boxes help you to build your models, simulate them and analyze their performance. 
BOND GRAPH
 BODE PLOT
• A Bode plot /ˈboʊdi/ is a graph of the frequency response of a system.
• It is usually a combination of a Bode magnitude plot, expressing the magnitude (usually in
decibels) of the frequency response, and a Bode phase plot, expressing the phase shift.
• The following image shows the bode plots of our transformer w.r.t frequency, magnitude (dB)
and phase (deg). These results are for the secondary side current of transformer.
• Similarly in the graph between frequency and phase we can see that there is no such effect on the
phases angle if the transformer is operated in the 10 KHz range.
 STEP FUNCTION

Step response is the time behavior of the outputs of a general system when its inputs change from
zero to one in a very short time. The step response of a dynamical system gives information on the
stability of such a system, and on its ability to reach one stationary state when starting from
another. From a practical standpoint, knowing how the system responds to a sudden input is
important because large and possibly fast deviations from the long term steady state may have
extreme effects on the component itself and on other portions of the overall system dependent on
this component.
STEP RESPONSE
 STATE SPACE

A state space system is represented by just two equations. First, the state equation gives the
relationship between the system’s current state and input to its future state. The output equation
gives the relationship between the system’s current state and input to its output.
STATE SPACE
 TRANSFER FUNCTION

In engineering, a transfer function (also known as system function or network function) of an

electronic or control system component gives the device's output for each possible input.
The units of the transfer function depend on the device. The term "transfer function" is also used in
the frequency domain analysis of systems using transform methods such as the Laplace transform;
here it means the amplitude of the output as a function of the frequency of the input signal. For
example, the transfer function of an electronic filter is the voltage amplitude at the output as a
function of the frequency of a constant amplitude sine wave applied to the input.
TRANSFER FUNCTION
 ZEROS AND POLES

Poles and Zeros of a transfer function are the frequencies for which the value of the denominator
and numerator of transfer function becomes zero respectively. The values of the poles and the zeros
of a system determine whether the system is stable, and how well the system performs. Control
systems, in the simplest sense, can be designed simply by assigning specific values to the poles and
zeros of the system.
ZEROS AND POLES
ZEROS AND POLES
THANK YOU FOR YOUR TIME

ANY QUESTIONS?