Calculations For Design Parameters of Transformer

11/26/2018 Calculations for Design Parameters of Transformer – Engineer Experiences
Calculations for Design Parameters of

Transformer
 October 14, 2016 (http://engineerexperiences.com/design-calculations.html)  Asad Ullah
(http://engineerexperiences.com/author/asad-ullah)  Article
(http://engineerexperiences.com/category/article), DIY (http://engineerexperiences.com/category/diy),
Project (http://engineerexperiences.com/category/project), Transformer
(http://engineerexperiences.com/category/transformer)
Table of Contents 
Design Parameters of Transformer

For Quick review and summary of Calculations, see the tables at the end of this article.
(Table 1) (https://lh3.googleusercontent.com/-
UqSM4KW7kTo/Vk1qeGGs9EI/AAAAAAAAAlc/5XNn4WQtgck/s512-
Ic42/primary.JPG) (Table 2) (https://lh3.googleusercontent.com/-
ZkfU3uUO96s/Vk1qeGyiVqI/AAAAAAAAAlg/tS1YlVeqW2M/s576-Ic42/secondary.jpg) For
better understandings, go through the following steps for calculations. Make sure you
have knowledge of Basics of Transfomer (http://engineerexperiences.com/transformer-
basics.html)
Design Parameters
For designing a transformer, we need:
1. Power rating
2. Voltage levels (primary and secondary)
3. Currents on both sides
4. Primary and secondary coils wire diameter/size
5. Iron Core area
6. Numbers of turns (primary and secondary)
We are going to design a 50 VA step down transformer of 230V to 12V. Necessary

calculations along with formulae are given below in details:
As we are going to design small transformer (of small power rating) so we are neglecting
core and copper losses as they doesn’t matters in small transformers 
(http://engineerexperiences.com/category/transformer)and seriously considered in
http://engineerexperiences.com/design-calculations.html 1/34
designing power transformers (high power rating transforms).
Calculations:
1. Core Calculations:
Calculate area of core (central limb) by using following formula:
Ai= area of core

F= operating frequency
Bm= magnetic flux density
Te= turns per volts (http://engineerexperiences.com/transformer-design-turns-per-
volts.html)
(for derivation of this formula Click Here (http://engineerexperiences.com/turns-per-volts-
transformer-design.html))
Assumptions:
So, we know the frequency of the power system. We need magnetic flux and turns per
volts. For designing a small transformer magnetic flux density is averagely taken as 1 to
1.2.
By putting values we will get the area of core.
Current density of copper wire is taken as 2.2 A / mm2 to 2.4 A/ mm2 (approximately).
So, putting values
F= 50 hz
Bm = 1.2 wb/m2
Te = 4 (turns per volts)
As, we are going to design a practical transformer

(http://engineerexperiences.com/category/transformer)so we must consider the core
available in market. The standard Bobbins available in market practically is 1”x1”,
1.25”x1.5”, 1.5”x1.5” and so on. We took nearest core area available to our calculation.
We took bobbin of 2.25 inch2 (1.5”x1.5”) or 0.00145161 meter square. We have the core
area. We can calculate turns per volts using this area by following:
Putting f=50 hz; Bm = 1.2 wb/(m^2); Ai= 0.001451 m^2, we
got:

So, Turns per volts are 2.6 Turns per volts. (http://engineerexperiences.com/turns-per-
volts-transformer-design.html)
Primary Winding Calculations

Primary voltage = Vp = 230 V
Primary current = I1= VA / Vp = 50 / 230 = 0.218
Let transformer we are going to design is 95 % efficient so,

I1 = VA/ (efficiency x Vp) = 0.23A
Primary Current = 0.23 Amp (approx.)
Number of Turns:
Total number of turns = turns per volts (http://engineerexperiences.com/turns-per-vol
ts-transformer-design.html) x primary side voltage
= 2.6 x 230
N1 = 600 turns (approximately)
Size of Conductor:
As we know that
As, for copper the current density is taken as 2.3 A per mm square So, for area of copper
conductor
From the standard American wire gauge table, we can choose wire of the same
thickness. It can be seen that it comes out that required primary side wire is of 27 gauge
which can conduct required current. (for AWG table Click here
(http://www.powerstream.com/Wire_Size.htm))
Selection of wire can also be done by calculating primary current and by cross match the
standard table of copper wire according to their current handling capabilities.
Secondary Winding Calculations


Secondary voltage = Vs = 12 V
Secondary current = Is = VA/ Vs = 50 / 12 = 4.2 Amp (approx.)
From the standard copper wire, table it can be seen that wire of this thickness is of 15
gauge. So for secondary winding we need 15 gauge wire.
So,
Secondary Wire =15 AWG
Number of Turns:
Number of secondary turns = turns per volts (http://engineerexperiences.com/turns-per
-volts-transformer-design.html) x secondary volts
N2 = 2.6 x 12 = 32 turns (approx.)
Weight Estimation of Windings

For weight calculations, following steps will be followed:
1. Approximate length of copper wire = perimeter of bobbin x number of turns

2. Cross sectional Area of copper conductor
3. Volume = Approximate length x Cross sectional area
4. Mass = density of copper x Volume
Density of copper = 8960 kg/ m3
Primary side:
Perimeter of bobbin = (1.75 x 4) = 7 inch = 0.1778 m
So,
Length of one turn = 0.1778 m

Total length of all turns of primary = L1
L1 = (length of one turn) x(total number of turns of primary)

L1 = 0.1778 x 600
L1 = 106 m (approx.)
As,
area of primary conductor = 0.1 mm2
= (0.1 x 10 ^ -6) m2
Volume of copper wire = area x length
volume of conductor
And density of copper = 8960 kg/ m3
So,
So we need approx. 100 grams of 27 gauge wire.
Secondary winding weight:

Perimeter of bobbin = (1.75 x 4) = 7 inch = 0.1778 m
So,
Length of one turn = 0.1778 m
Total length of all turns of Secondary
= L2 = length of one turn x total number of turns of secondary
L2 = 0.1778 x 32
L2 = 6 m (approx.)
As,
area of primary conductor = 1.83 mm2 = (1.83 x 10 ^ -6) m2
Volume of copper wire = area x length 
So, we need approx. 100 grams of 15 gauge wire.
So, from above calculations we can summarize in following table:
(https://i0.wp.com/lh3.googleusercontent.com/-
UqSM4KW7kTo/Vk1qeGGs9EI/AAAAAAAAAlc/5XNn4WQtgck/s512-
Ic42/primary.JPG?ssl=1)
Table 1: Calculation for primary side
---------------------------------------------------------------------------------------------------------------------
(https://i2.wp.com/lh3.googleusercontent.com/-
ZkfU3uUO96s/Vk1qeGyiVqI/AAAAAAAAAlg/tS1YlVeqW2M/s576-
Ic42/secondary.jpg?ssl=1)
Table 2: Design Summary for Secondary of transformer design
At this point you have done the Calculations and you have the characteristics of
transformer components. Now, for making in hard form, see few easiest steps of
hardware implementation of calculations (http://engineerexperiences.com/hardware-
design-.html):
Here is another article for transformer core optimization using Genetic Algorithm
(http://engineerexperiences.com/transformer-core-optimization-using-genetic-algorithm-
ga.html) - a heuristic method of optimization.
For any Queries and further Assistance, feel free to comment below and like
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ASAD ULLAH (HTTP://ENGINEEREXPERIENCES.COM/AUTHOR/ASAD-ULLAH)
I am MSc Scholar in Electrical Engineering. Working with Modeling and Simulation

software related to my eld are my activities in leisure.
99 thoughts to “Calculations for Design Parameters of

Transformer”
M ADNAN
November 6, 2018 at 8:20 pm (http://engineerexperiences.com/design-calculations.html#comment-587)
what is the formula to calculatre te area of auto transformer?
REPLY (HTTP://ENGINEEREXPERIENCES.COM/DESIGN-CALCULATIONS.HTML?REPLYTOCOM=587#RESPOND)
G.
September 27, 2018 at 12:17 pm (http://engineerexperiences.com/design-calculations.html#comment-561)
You give formula parameters to use that do NOT make any sense then you solve an
equation BUT DO NOT Explain how you derived at simpli ed variable sub totals and
then give a resultant. For example: F= 50 hz
Bm = 1.2 wb/m2
Te = 4 (turns per volts)
Ai= 9.384 × 10-4m 2 ~1.45 inch sq. Really? Are you assuming your viewing audience
has taken advanced algebra or is space as a premium you can't explain how you did
this or are you just too damn lazy to explain how you got there?
AS the saying goes ----it's like listening to one engineer talk another.

MIRCEA
There is a formula in "1.Core Calculations." He gives you values for all variables
except one. Then he computes the unknown one. I learned to do that when I was
3rd grade in school. Where do you come from?
ANONYMOUS
July 16, 2018 at 12:29 pm (http://engineerexperiences.com/design-calculations.html#comment-515)
hello sir can you make also a calculation for toroidal transformer?
ASAD ULLAH
Unfortunately, toroidal transformer calculations are not available currently.
ANONYMOUS
Hello sir, can i apply this on SWG magnetic wire? We dont use here in philippines AWG
table. There is a big di erence on AWG ang SWG
Thank you
ASAD ULLAH
You can calculate the current in each winding and according to maximum current,
you can choose wire from wire gauge table of your ease.
Hope you got your answer. 

BILLY BOB
August 31, 2018 at 9:42 pm (http://engineerexperiences.com/design-calculations.html#comment-539)
If i sent you a nameplate from a transformer do you think you could estimate the
copper content of the transformer with much accuracy?
ASAD ULLAH
September 3, 2018 at 12:13 pm (http://engineerexperiences.com/design-calculations.html#comment-
540)
you can check by yourself according to power rating.

I can give it try. you can send on email address. engineerexperiences@gmail.com
(mailto:engineerexperiences@gmail.com)
DEN
June 18, 2018 at 8:46 pm (http://engineerexperiences.com/design-calculations.html#comment-495)
Anyone knows why the e ciency e ect is only applied on primary current ?? How
about the secondary current?
And also what should I do if I require 50% margin for core area? Why is also the
perimeter value is using 1.75 instead of 1.5??
ASAD ULLAH
primary side current is responsible for induction in secondary side as well as losses
in core for magnetization and de-magnetization. That's why primary side current is
considered for e ciency.
Yes, the perimeter should be 1.5 instead of 1.75
ASAD ULLAH
1.75 is not wrong (to some level). As we are not taking other parameters into
account for winding. So, Doesn't matter here (to this level of design)
OLAJIDE TAIWO
June 15, 2018 at 5:34 am (http://engineerexperiences.com/design-calculations.html#comment-493)
Thank you for your design of this single phase transformer, all your explanations are
very clear and straight to the point.
It will be very nice if you could please let us have also a design for a three phase
transformer.
Thanks a lot.
Jide T.
EBENEZER SMART
thanks a lot sir,

sir, for someone to design a transformer of 10,000 watts, what size of wire will be
needed, cause according to your formula the value am getting is excess and I couldn't
see the value i got in the wire Gage data sheet
ASAD ULLAH
As mentioned in article, this method is good and suitable for designing small
transformers. For high power transformer, other factors a ects too.
Anyways, just as a tip: for current handling you can use copper strips for winding
and use multiple parallel paths for same winding. (i.e. multiple parallel conductor
bars to handle. If a bar handles 10Amps max, you can use two parallel bars for
20Amps.) Again, it is just a tip. use on your own risk.
P.S: But the use of strips are valid. 
MIRCEA BUJOR
Hi, Is it ok to use 4A/mm2 current density in a toroidal transformer? I understand

your design is for square transformer.
ASAD ULLAH
These calculations cum assumptions are for designing of soft silicon steel based
core transformers. As far i know, torodial transformers have core of other iron,
cobalt, manganese alloy. So, i can't comment about current density for that
currently.
Anyhow, That cores requires less energy to energize with higher current densities to
handle... exact gure, i can't comment at moment.
ABDUL SAMAD
May 28, 2018 at 2:17 am (http://engineerexperiences.com/design-calculations.html#comment-484)
Most helpful article.I appreciate your work.Great sir
VIJAY VARSANI (HTTPS://PLUS.GOOGLE.COM/107104542531903722132)

May 19, 2018 at 7:19 pm (http://engineerexperiences.com/design-calculations.html#comment-480)
2x5=10" a\ 60000 fd \ 50hz\ 4.44 gus equatane is t=100000000/4.44*hz*fd*a .... so

your t=0.75v
so if you wont 90v taping so 90*0.75=67.5t if you wont 230 v so 230*0.75=172.5t

TEBOGO
Sir help me understand how to do calculations for transformer power rating.How do

you decide on the size of your transformer in kVA or MVA?
ASAD ULLAH
Power rating of transformer depends on the use of transformer. VA, kVA, MVA
depends on your application of transformer.
TEBOGO
Sir what is the shape of this bobbin and which side are you referring to since we used
a 1.5inchx1.5inch bobbin?
ASAD ULLAH
http://engineerexperiences.com/hardware-design-.html
(http://engineerexperiences.com/hardware-design-.html)
hope this link will help you.
FAIZAN AHMAD
its very help full article.

ANONYMOUS
GREAT sir!
VIRENDRA SINGH
Above Calculation based on the Value Te=4 Turn Per Volt. What is bene t/drawback if
we choose a big/small size of Bobbin
ASAD ULLAH
bobbin size is, somewhat mechanical parameter which decides size of your
transformer. Greater size bobbin will only increase cost and weight of transformer
material. Smaller bobbin will not be able to hold enough steel core for required
power transfer (from primary to secondary).
MUNAWAR
April 15, 2018 at 7:36 am (http://engineerexperiences.com/design-calculations.html#comment-454)
is it possible to put a 500kva transformer winding in another 500kva transformer core

????
ASAD ULLAH
April 16, 2018 at 11:09 pm (http://engineerexperiences.com/design-calculations.html#comment-456)
if both are designed to serve the same purpose, there is nothing wrong replacing
one's winding with other's.
VICTOR AGBEBI
I need to construct a 1.5kVa transformer with 12-0-12 primary and 220V secondary.
What is the wire guage needed and number of turns.kindly help
ASAD ULLAH
Just follow the formula given above. Nothing will change except the power ratings.
Two windings of same ratings with be there on secondary side.
FREEDOM PHILIP LACHICA (HTTPS://PLUS.GOOGLE.COM/117006796292632589202)

March 22, 2018 at 9:09 pm (http://engineerexperiences.com/design-calculations.html#comment-435)
sir, can the size of the copper wire a ect the number of turns? if it can, how so?
because, as how I understand the solution above, it seems it does not a ect. sorry,
I'm a newbie. and moreover, we would like to design a 15VA, 220/30 V single phase
transformer. we already have 1.25"x1.25" bobbin and a number 25 gauge wire. how
can we determine the number of turns?
ASAD ULLAH
size of copper wire is e ected by the current. Number of turns on other hand,
related to voltage (actually to the generation of magnetic ux and ultimately to
voltage generation). So, as in article, number of turns are calculated according to
voltage requirement and copper wire gauge is calculated by current requirements.
Hope you got your answer.
SANTOSH
March 22, 2018 at 9:12 am (http://engineerexperiences.com/design-calculations.html#comment-434)

Sir mai 5kva 8no. Core me(input=90v - 300v) automatic stabilizer banana chahata hu
to sir mai kaise calculate kr k turn nikalu.
ASAD ULLAH
Calculate turn and wire gauge for each voltage level at secondary. Obviously, you
want some steps between these voltage levels so there will be as much number of
windings as the number of steps of voltages of secondary. Then by the use of relays,
voltage sensor and micro-controller programming, you can make this automatic.
SANTOSH
Sir mere paas 7no. core(2" * 5") hai to sir mai (input= 90v-300v) tk ka automatic
voltage stabilizer ka coil banana chahata hu.
to sir mai kaise calculate kr k turn nikalu.
Plzz bataeye.
ANONYMOUS
where is the EI iron core detail
ASAD ULLAH
http://engineerexperiences.com/transformer-basics.html
(http://engineerexperiences.com/transformer-basics.html)
Hope you can nd enough to understand here.
GUPTAN VEEMBOOR
Thanks for this simple explanation. I am an eighty year old man retired and going
through these things just to while away the time. I have some engineering
background. But have forgotten everything- practically. Thanks once again.
Regards, Guptan
RALPH
February 18, 2018 at 7:54 pm (http://engineerexperiences.com/design-calculations.html#comment-421)
Does this applicable for multi-winding transformers with di erent voltage and current
rating in every windings.
ASAD ULLAH
Yes, if you calculate each winding di erently.
NADEEM BUTT
sir , what is pulse transformer & how to make it .for fence charger input 350-400 volt
& output 5000-9000 volt in pulse with 8 mill ampere
NDAYISABA THEONESTE
January 17, 2018 at 3:51 pm (http://engineerexperiences.com/design-calculations.html#comment-407)
i kneed your helper i want to design a step up transformer of 150VA primary voltage
is75v and secondary voltage is 220V
ASAD ULLAH
January 20, 2018 at 11:45 am (http://engineerexperiences.com/design-calculations.html#comment-408)
Calculations will be same as said in article. just change the voltage levels and you'll
get currents and nd number of turns and wire gauges accordingly.
ANONYMOUS
December 28, 2017 at 8:18 pm (http://engineerexperiences.com/design-calculations.html#comment-400)
I want to learn about electrical experience more and more.
NOOMAN KHAN
how to nd the bobbin size from power (VA) rating of transformer ?
ASAD ULLAH
Actually, VA rating does not have direct a ect on bobbin size. It depends on
maximum ux density, number of turns and material for core. In this article, we are
using laminated stripped iron core and taking standards for maximum ux density
and number of volts per turns.
I hope you get your answer.
ABHILASH ROUTRAY
October 11, 2017 at 9:23 am (http://engineerexperiences.com/design-calculations.html#comment-354)
F= 50 hz
Bm = 1.2 wb/m2
Te = 4 (turns per volts) 
How did u get te =4 turns per volt?
ASAD ULLAH
The turns per volts are assumptions is constant and almost standardized for
designing small transformer.
Actually, magnetic ux density is standard and turns per volt are calculated using
that value. You can check derivation on an article linked below:
http://engineerexperiences.com/turns-per-volts-transformer-design.html
(http://engineerexperiences.com/turns-per-volts-transformer-design.html)
INAYAT
October 7, 2017 at 1:23 pm (http://engineerexperiences.com/design-calculations.html#comment-351)
Sir kindly answer my question

I made a transformer which have primery winding is 220 turn(18 swg wire 1kg) and
secondary turn is 22 turn(10 swg 650gram) now the input voltage is 210 volt and
output is 18 volt
bobin size is ( 6inch×3inch) how much current given in output ?????
Plz answer my question
ASAD ULLAH
As per calculations, you have current ratio of 1:10 (primary to secondary). Now, as
you have 18 SWG so it can have max of 3Amp. So, it can have 3amp to primary and
almost 25~30Amp at secondary (at max).
PHIWE (HTTP://ENGINEEREXPERIENCES.COM)
I AM CONFUSED BY THE VERY FIRST FORMULA BECAUSE YOU SAY THAT Bm IS

MAGNETIC FLUX_Phi_(Wb) AND YET YOU SUBSTITUTE THE MAGNETIC FLUX

DENSITY(Wb/m^2) HOW SO???
ASAD ULLAH
It is actually magnetic ux density, no matter the nomenclature in the article it is still

magnetic ux density.
Pingback: How to calculate Toroidal Core Maximum VA capacity | Page 4 | Physics Forums - The Fusion of
Science and Community (https://www.physicsforums.com/threads/how-to-calculate-toroidal-core-
maximum-va-capacity.876425/page-4#post-5849121)
ADNAN KHAN
Sir ma transformer banana chatha ho mera pas iron core pare ha his ma 3.8cm5cm
ha moja wire no bata dena tarn me tadad be secondary or prembry Dino ma ma an
pard ho koch moskil aya gee please ap mer madad kro thanks
ASAD ULLAH
You want transformer of which ratings ? Wire size depends on power ratings of
transformer.
ROBERT ROSS (HTTP://WWW.IDIOMS4YOU.COM)

September 1, 2017 at 2:14 am (http://engineerexperiences.com/design-calculations.html#comment-325)
Asad, This page is absolutely fantastic. Thank you very much. In the above, "1.75 is the
length of one side of the bobbin." In the example on this page, I understood that a
standard size of 1.5 inches by 1.5 inches was used for the example calculations. Could
you please help me understand where the 1.75 inches is derived from?

SHIVAM PATEL
Sir,I made a transformer 24V 3A,72VA operated in 220V which heated more without
load..and output is accurate, bobbin area is 10.26sqcm , primary turn 937 , turn per
volt 4.26, secondary turn 106 ,primary wire gauge 28, secondary wire gauge 19 can
anyone please explain why so heated?????thanks
ASAD ULLAH
September 1, 2017 at 8:34 am (http://engineerexperiences.com/design-calculations.html#comment-326)
Heating could be due to low quality core material or loose binding of core (air
between core stampings) as a lot of power is being lost in it. Use laminated core
stamping for core and hard bind them to avoid losses.
BOBBY
pls for large transformer power like 6kva, how will i get the value of ux density (Bm)
AMABO
By using the same perimeter value for both primary and secondary, you implicitly
assume that windings are side by side (split bobbin) rather than one over the other.
Standard practice is to use not perimeter but mean length of term (MLT), thus the
stated wire lengths are too long. The winding area is not lled 100% because the wire
is round and has air included in the winding cross section. Standard practice is to use
a ll factor which tends to be around 60% when winding technique and insulation
thickness are included. This a ects the choice of wire gauge to t the cross section.
From wire length and gauge the next step is to calculate resistances from which the
voltage drops can be known, noting that AC resistance will be somewhat greater than
DC resistance. Then the design can be iterated to compensate.
REPLY (HTTP://ENGINEEREXPERIENCES.COM/DESIGN-CALCULATIONS.HTML?REPLYTOCOM=301#RESPOND) 
ASAD ULLAH
Yes you are right. I am aware of 'mean length per turn', 'window e ective area',
resistance of winding, core geometrical constants and many more factors according
to which transformer is designed. Here, we have designed small transformer and
with compensation factor, some parameters are neglected and some are included
in compensation factor.
Thank you for your considerations. Design calculations according to all these factor
included will be available soon.
BEHZAD
July 29, 2017 at 3:32 am (http://engineerexperiences.com/design-calculations.html#comment-291)
as i gured out, all the formulas work only for ac input. what about a rectangular
pulse? should i use Fourier expression o voltage and then nd EMF equation?
FAISAL JAVAID
most help full artical or information....welldone

Asad bhai aap transfomer ka temprature rise nd out kr skty hain to kinly mari kuch
help kr dain aur L.T ,H.T eddy loss formula k bary ma b bta dain....Thanks
ANONYMOUS
How to make welding transformer?
ADEH AUGUSTINE

Mr Asad thank you for your explanation. Please I have a problem similar to this...am
asked to nd the parameters of a Transformer core (shell type) such as height(H),
diameter(D), width(W), width and length of the window slot(Ws). Haven being given
insulation thickness as 2mm, V=220/18v, P=450W, power factor as 0.8, window factor
as 0.3, maximum ux density(Bm=0.42T), F=50Hz, k=1.2.
Please how can I go about this.
MOHAMMED IDREES
What is current density for aluminium? Is the current density value is xed?
ASAD ULLAH
Yes, every material (conductor) have its constant current density as it is property of
material. Aluminum has current density of around 0.5 A/mm^2
MOHAMMED IDREES
How to design k rated transformer
STANLEY IZEBHOKHAE
bobbin of 2.25 inch2 (1.5”x1.5”) or 0.00145161 meter square. how dis you get
0,00145161!
ASAD ULLAH
2.25 inch square = 0.001455161 meter squares

it's simple area units conversion.
SYED
asslamwalkum sir can i u please explaine me the core calculation of CT
ASAD ULLAH
CT is a transformer with very low voltage drop at primary side and it is stepped up
for measurement. Core calculation for small CTs is almost same as other
transformers but for very small sized CTs, ferrite core is used which need di erent
set of calculations.
KUSHAL TRIVEDI
April 30, 2017 at 1:11 am (http://engineerexperiences.com/design-calculations.html#comment-232)
Respected sir,how we nd the laminations size if it is NOT C.R.G.O. IT IS C.R.N.G.O
PRIYANKA NAIK
Thank you for explaining the design of transform. I have one confusion that Perimeter
of bobbin=1.75 * 4 you have taken but 1.75 where it comes from???

ASAD ULLAH
1.75 is length of one side of bobbin. To calculate length of one complete revolution
of wire around bobbin it is multiplied by 4.
SYED HEDAYAT HUSSAIN ZAIDI

Dear Mr. Asad-ullah Sahab. Your Article is very informative and help full. thanks for
sharing it. Regards, May Allah live you long..
IDREES
How to choose ux density? Whether it wil vary for 3 phase transformers?
AKOS
When you calculate the core area you assumed Te = 4 (turns per volts) but it was not
clear where this number 4 comes from. In other calculations the core area is
proportional to the squareroot of VA and approximated as Ai = 1.152*sqrt(Output
voltage x output current) = 1.152*sqrt(50VA) = 8.146 cm^2=8.146*10^-4 m^2 and then
using this Ai value the turns per volt is calculated Te = 1/(4.44AiBf) = 1/(4.44 *
8.146*10^-4m^2 * 1.2T * 50Hz) = 4.6 turns per volts which is close to 4 that you
assumed. So actually the turns per volts come from the area and not in the other way
because the are comes from the VA. So we don't have to assume anything because
everything comes from somewhere.
Apart from this your work is nice. That was the only thing that was not
understandable and i had to look it up. Thanks for your post.
ASAD ULLAH
That's good thing you took interest and did research in this. But if you look into
literature of transformer design, some parameters are constant for speci c core
size and speci c material. You can nd standard tables in many books which give
you constant values for calculated core sizes. This 4 turns per volt is from standard
table for small transformer design calculation listed in Book by "R.K Agarwal" under
the title of " Principles of Electric Machine Design"
P TIRUPATHI RAO
for design purpose how much power factor will take for distrubution transformer
ASAD ULLAH
For designing a transformer, power factor is not a thing to consider as it depends

upon load on transformer. This is one of the important reasons that transformer
ratings are in VA (or kVA or MVA).
YILLIANG PENG (HTTP://WWW.EPE.COM.AU/MAINTENANCE-SERVICE/REWINDS/)

February 18, 2017 at 4:09 am (http://engineerexperiences.com/design-calculations.html#comment-147)
Thank you so much for explaining the parameters of transformers so precisely. My

wife was trying to gure out the area of the core; however, did not understand which
formula to use. This information de nitely makes it easy for us to just plug in our
information -- thank you! We did not know that you could just assume the
transformers magnetic ux. Thank you again for the information!
DHANASEKAR S
February 4, 2017 at 11:38 am (http://engineerexperiences.com/design-calculations.html#comment-128)
NEED 3 PHASE LAMINATED TRANSFORMER CORE WEIGHT CALCULATION FORMULA IN

SIMPLE METHOD..?
CAN U PLS HELP ME....?
ASAD ULLAH
These calculations are for single phase transformer design. For 3 phase
transformer, calculations and formulas are di erent. (this article will be available
soon)
You can design three phase transformers by connecting three single phase
transformers in star. (I personally designed and used it). During connections you
must take into considerations phase sequence of all transformers.
ALMAS (HTTP://ENGINEEREXPERIENCES.COM/DESIGN-CALCULATIONS.HTML)
‫ﻣﺣﺗرم اﺳد ﷲ ﺻﺎﺣب‬

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‫ ووﻟٹ ﭨراﻧﺳﻔر ﻣر ﺑﻧﺎﻧﺎ ﮨﮯ ﮨﮯ۔ ﮐﯾﺎ آپ ﻣﯾری ﻣدد ﮐر ﺳﮑﺗﮯ ﮨﯾں؟ اﻟﻣﺎس ﺷﮩزاد‬12
ASAD ULLAH
Yes! some times graphite core transformers are used in high frequency
applications. Its not something you can generalize about "going out" of iron core
transformers.
For that transformers use same calculations for wire of primary and secondary and
calculate total area covered by winding according to which you can nd out window
are and nd graphite core of that size.
ALMAS (HTTP://ENGINEEREXPERIENCES.COM/DESIGN-CALCULATIONS.HTML)
Asad Ullah! Thank to reply. you can guide me further to make step down
transformer using ferrite core or give me any link with will be informative for me?
PARAG REKHI
I want calculations for low watts . Ma transformer is pri 220v /sec 1000v and current is
50 ma .
Second transformer is pri 400v sec 5 v and current is 5 ma ...can you help me
ASAD ULLAH
Calculations for the wire would be same as for others. If you don't nd wire of your
desire rating, use smallest ( say 30 AWG wire) to wound your transformer. Your rst
transformer is of course falls in category of high voltage so lamination precautions
must be followed. Likewise, you can design second transformer.
LOGANATHAN
hi... thank u for this article. upto which power rating core & copper losses r
neglected..
ASAD ULLAH
Mostly, for Calculation of small transformers core losses are neglected (mostly small
transformer are considered up to 1000 VA).
However, plus minus 5 percent of turns of secondary winding is added to overcome
losses or get full voltage in full load conditions.
ANDREW
December 23, 2016 at 3:13 am (http://engineerexperiences.com/design-calculations.html#comment-111)
Hi, thank you for your article. On the core calculations section, could you explain
where you got the 4 turns per volt from that is needed to plug into the equation to
calculate the core area. Also, in the same equation, the constant 4.44 - what does this
represent? Thank you
ASAD ULLAH
December 25, 2016 at 8:55 am (http://engineerexperiences.com/design-calculations.html#comment-112)
For design of small transformer some assumptions have to made. Turns per volts
here are from a standard table of designing transformer. (you can study it in book
"Principles of Electric Machine Design by R.K Agarwal" or any transformer design
book). This is according to transformer type and rating.
4.44 is constant in equation of turns per volts comes while deriving this equation
with help of fundamental equations.(click link below for detail derivation).
http://engineerexperiences.com/turns-per-volts-transformer-design.html
(http://engineerexperiences.com/turns-per-volts-transformer-design.html)
Hope you get your answer.
NERVIC
4.44 comes from the rms formula derivation.
TYLER BROOKS

Hey just wanted to say thanks you for all of these great articles! They read very very
well and you've covered all of my questions.
MD KAWSER AHMED (HTTPS://PLUS.GOOGLE.COM/104970073673962513929)

Great... Thanks.
ISHTIAQ
October 27, 2016 at 10:59 pm (http://engineerexperiences.com/design-calculations.html#comment-29)
At 60 hz frequency what will be ux density
ASAD ULLAH
As per formula given in start of article, ux density and frequency are inversely
related. But, normally in designing ux density is taken constant (as ux required is
constant and area is constant). So, if frequency changes the compensation is made
on voltage side. i.e. transformer will be designed accordingly with voltages. but in
small transformers such parameters are neglected mostly. (but if you want to, Bm
will be constant and voltages will be changed.) P.S: sometimes tolerance voltage
compensate this change.
WHAT DO YOU THINK?
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Calculations For Design Parameters of Transformer

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11/26/2018 Calculations for Design Parameters of Transformer – Engineer Experiences

Calculations for Design Parameters of

Design Parameters of Transformer

We are going to design a 50 VA step down transformer of 230V to 12V. Necessary

(http://engineerexperiences.com/category/transformer)and seriously considered in

designing power transformers (high power rating transforms).

Ai= area of core

As, we are going to design a practical transformer

Primary Winding Calculations

Let transformer we are going to design is 95 % efficient so,

Secondary Winding Calculations

Secondary current = Is = VA/ Vs = 50 / 12 = 4.2 Amp (approx.)

Secondary Wire =15 AWG

N2 = 2.6 x 12 = 32 turns (approx.)

Weight Estimation of Windings

1. Approximate length of copper wire = perimeter of bobbin x number of turns

Density of copper = 8960 kg/ m3

Perimeter of bobbin = (1.75 x 4) = 7 inch = 0.1778 m

Length of one turn = 0.1778 m

L1 = (length of one turn) x(total number of turns of primary)

And density of copper = 8960 kg/ m3

So we need approx. 100 grams of 27 gauge wire.

Secondary winding weight:

Length of one turn = 0.1778 m

Total length of all turns of Secondary

= L2 = length of one turn x total number of turns of secondary

Volume of copper wire = area x length 

So, we need approx. 100 grams of 15 gauge wire.

So, from above calculations we can summarize in following table:

Table 1: Calculation for primary side

Table 2: Design Summary for Secondary of transformer design

Transformer Basics (http://engineerexperiences.com/tag/transformer-basics)

Transformer Calculations (http://engineerexperiences.com/tag/transformer-calculations)

ASAD ULLAH (HTTP://ENGINEEREXPERIENCES.COM/AUTHOR/ASAD-ULLAH)

I am MSc Scholar in Electrical Engineering. Working with Modeling and Simulation

99 thoughts to “Calculations for Design Parameters of

what is the formula to calculatre te area of auto transformer?

Unfortunately, toroidal transformer calculations are not available currently.

Hope you got your answer. 

you can check by yourself according to power rating.

Yes, the perimeter should be 1.5 instead of 1.75

thanks a lot sir,

Hi, Is it ok to use 4A/mm2 current density in a toroidal transformer? I understand

Most helpful article.I appreciate your work.Great sir

VIJAY VARSANI (HTTPS://PLUS.GOOGLE.COM/107104542531903722132)

2x5=10" a\ 60000 fd \ 50hz\ 4.44 gus equatane is t=100000000/4.44*hz*fd*a .... so

Sir help me understand how to do calculations for transformer power rating.How do

its very help full article.

is it possible to put a 500kva transformer winding in another 500kva transformer core

April 2, 2018 at 1:20 pm (http://engineerexperiences.com/design-calculations.html#comment-448)

FREEDOM PHILIP LACHICA (HTTPS://PLUS.GOOGLE.COM/117006796292632589202)

where is the EI iron core detail

March 6, 2018 at 9:40 am (http://engineerexperiences.com/design-calculations.html#comment-426)

Yes, if you calculate each winding di erently.

I want to learn about electrical experience more and more.

how to nd the bobbin size from power (VA) rating of transformer ?

Sir kindly answer my question

I AM CONFUSED BY THE VERY FIRST FORMULA BECAUSE YOU SAY THAT Bm IS

It is actually magnetic ux density, no matter the nomenclature in the article it is still

ROBERT ROSS (HTTP://WWW.IDIOMS4YOU.COM)

most help full artical or information....welldone

How to make welding transformer?

How to design k rated transformer

2x5=10" a\ 60000 fd \ 50hz\ 4.44 gus equatane is t=100000000/4.44hzfd*a .... so