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PENGERTIAN TRANSFORMATOR
ELECTRIC
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Transformator atau sering juga disebut trafo adalah komponen elektronika pasif yang
berfungsi untuk mengubah (menaikkan/menurunkan) tegangangan listrik bolak-balik
(AC)
Bentuk dasar transformator adalah sepasang ujung pada bagian primer dan sepasang
ujung pada bagian sekunder. Bagian primer dan skunder adalah merupakan lilitan kawat
email yang tidak berhubungan secara elektris. Kedua lilitan kawat ini dililitkan pada
sebuah inti yang dinamakan inti trafo. Untuk trafo yang digunakan pada tegangan AC
frekuensi rendah biasanya inti trafo terbuat dari lempengan2 besi yang disusun menjadi
satu membentuk teras besi. Sedangkan untuk trafo frekuensi tinggi (digunakan pada
rangkaian2 Radio Frequency/RF) menggunakan inti ferit (serbuk besi yang dipadatkan).
Pada penggunaannya trafo juga digunakan untuk mengubah impedansi. (hah makanan
apaan tuh impedansi?!)
Wah kalo ngejelasin impedansi bakal habis postingan ini, ntar deh saya jelaskan tentang
impedansi lain waktu aja ya :-). Balik lagi ke trafo, untuk trafo frekuensi rendah
contohnya adalah trafo penurun tegangan (Step Down Trafo) yang digunakan pada
peralatan2 elektronik tegangan rendah, adaptor, pengisi battery dsb. Trafo jenis ini jika
pada bagian primernya kita hubungkan dengan tegangan AC misalnya 220 volt maka
pada bagian skundernya akan mengeluarkan tegangan yang lebih rendah. Pada rangkaian
tersebut trafo berfungsi untuk menurunkan tegangan AC dari jala-jala PLN yang 220 volt
menjadi sebesar tegangan yang dibutuhkan peralatan tersebut agar dapat bekerja normal,
misalnya 3 volt, 6 volt atau 12 volt dsb.
Sementara itu trafo penaik tegangan (Step Up Trafo) adalah kebalikan dari step down
trafo yaitu untuk menaikkan tegangan listrik AC. Sebuah trafo penurun tegangan bisa
juga kita gunakan untuk menaikkan tegangan dengan membalik bagian primernya
menjadi skunder dan bagian skunder menjadi primer, tentu dengan memperhatikan
tegangan kerja trafo tersebut. Contoh penggunaan trafo penaik tegangan adalah pada
rangkaian emergency light/lampu darurat yang menyala saat PLN padam dan UPS pada
PC. Prinsip kerjanyanya adalah tegangan DC (searah) yang berasal dari battery diubah
menjadi tegangan AC (bolak-balik) lalu dinaikan menjadi 220 volt oleh trafo sehingga
mampu menyalakan lampu atau PC di saat PLN padam.
Secara (bukan karena;-)) prinsip trafo penurun tegangan adalah jumlah lilitan primernya
lebih banyak dari pada jumlah lilitan skundernya. Sedangkan trafo penaik tegangan
memiliki jumlah lilitan primer lebih sedikit dari pada jumlah lilitan skundernya. Jika
dilihat dari besarnya ukuran kawat email yang digunakan, trafo penurun tegangan
memiliki ukuran kawat yang lebih kecil pada lilitan primernya. Sebaliknya trafo penaik
tegangan memiliki ukuran kawat yang lebih besar pada lilitan primernya. Hal ini
dikarenakan pada trafo penurun tegangan out put (keluaran) arus listriknya lebih besar,
sedangkan trafo penaik tegangan memiliki out put arus yang lebih kecil. Sementara itu
frekuensi tegangan pada in put dan out putnya tetap (tidak ada perubahan). Parameter lain
adalah efisiensi daya trafo. Dalam kinerjanya trafo yang bagus memiliki efisiensi daya
yang besar (sekitar 70-80%). Daya yang hilang biasanya keluar menjadi kalor/panas yang
timbul pada saat trafo bekerja. Trafo yang memiliki efisiensi tinggi dibuat dengan teknik
tertentu dengan memperhatikan bahan inti trafo, kerapatan lilitannya serta faktor2
lainnya.
Untuk mengetahui sebuah trafo masih bagus atau sudah rusak adalah dengan
menggunakan AVO meter. Caranya posisikan AVO meter pada posisi Ohm meter, lalu
cek lilitan primernya harus terhubung. Demikian juga lilitan sekundernya juga harus
terhubung. Sedangkan antara lilitan primer dan skunder tidak boleh terhubung, jika
terhubung maka trafo tersebut konslet (kecuali untuk jenis trafo tertentu yang memang
didesain khusus untuk pemakaian tertentu). Begitu juga antara inti trafo dan lilitan
primer/skunder tidak boleh terhubung, jika terhubung maka trafo tersebut akan
mengalami kebocoran arus jika digunakan. Secara fisik trafo yang bagus adalah trafo
yang memiliki inti trafo yang rata dan rapat serta jika digunakan tidak bergetar, sehingga
efisiensi dayanya bagus. Dalam penggunaannya perhatikan baik2 tegangan kerja trafo,
tiap tep-nya biasanya ditulis tegangan kerjanya misalnya pada primernya 0V - 110V -
220V, untuk tegangan 220 volt gunakan tep 0V dan 220V, sedangkan untuk tegangan
110 volt gunakan 0V dan 110V, jangan sampai salah atau trafo kita bakal hangus! Dan
pada skundernya misalnya 0V - 3V - 6V - 12V dsb, gunakan 0V dan tegangan yang
diperlukan. Ada juga jenis trafo yang menggunakan CT (Center Tep) yang artinya adalah
titik tengah. Contoh misalnya 12V - CT - 12V, artinya jika kita gunakan tep CT dan 12V
maka besarnya tegangan adalah 12 volt, tapi jika kita gunakan 12V dan 12V besarnya
tegangan adalah 24 volt.
Besarnya arus listrik yang bisa di supply oleh sebuah trafo biasanya juga dicantumkan
misalnya 0.5 Amp, 1 Amp, 5 Amp dsb. Sesuaikan dengan kebutuhan jika membeli atau
menggunakannya agar bisa berfungsi normal dan efisien.
Jenis2 trafo yang lain adalah trafo OT(Output Trafo) dan IT(Input Trafo). Trafo jenis ini
banyak digunakan pada peralatan audio. Untuk trafo frekuensi tinggi mungkin nanti akan
kita bahas pada bagian Radio Frekuensi (RF) karena penggunaannya lebih banyak dalam
rangkaian2 RF.
Trafo atau Tranformator adalah suatu alat yang berfungsi menaikkan dan menurunkan
tegangan listrik arus bolak-balik, dari tegangan tertentu menjadi lebih tinggi atau lebih
rendah.
Yaitu jumlah lilitan Primer lebih sedikit dibanding jumlah lilitan sekunder.
2.Trafo step down (menurunkan tegangan)
Yaitu jumlah lilitan primer lebih banyak dibanding jumlah lilitan sekunder.
Komponen yang dibutuhkan untuk membuat trafo terdiri dari Tiga komponen pokok
yaitu:
1.Kern (inti besi)
2.Kawat tembaga (kawat email).
3.Koker (tempat melilit kawat).
Semua Komponen yang dibutuhkan untuk membuat Trafo, banyak tersedia di pasaran.
Contoh Membuat Trafo 250W. (input :220v, output: 24v ct. 24v, )
5 Amper
Seperti yg telah saya jelaskan diatas, kita tidak perlu pusing menghitung angka-angka
matematika, tetapai kita mulai dari cara yang sudah dicoba dan sudah berhasil.
Ukuran inti untuk Trafo 250W kita menggunakan Kern dengan ukuran lebar inti 3,2cm,
tebal susunan kern akan didapat 5cm. (hitungan tersebut berasal dari akar 250 = 15,81.
karena menggunakan kern ukuran 3,2 cm sehingga didapat 1 5,81 / 3,2 = 4,9.
dibulatkan keatas menjadi 5cm. ).
Jumlah lilitan kawat email, untuk Trafo 250w adalah 3 lilitan / volt, sehingga untuk
tegangan primer (220V) didapat 660 lilit.
Diameter kawat primer antara 0,4 - 0,45 mm . namun sebagai tahap awal saya sarankan
gunakan dulu ukuran kawat primer 0,40mm, dengan pertimbangan anda belum mahir
menyusun gulungan kawat dengan rapih. untuk tegangan skundernya (24v ct 24v) kita
gunakan kawat email dengan diameter 0,85mm,
Jumlah lilitan skunder ( untuk tegangan 24V ct 24V ) hitungannya tentu
( 24 +24 = 48V . 48 lilit X 3 lilit =144 Lilit ).
Transformator
http://smandatas.com
Transformator terdiri atas sebuah inti, yang terbuat dari besi berlapis
dan dua buah kumparan (lilitan kawat), yaitu kumparan primer dan
kumparan sekunder.
Keterangan :
Jenis-jenis transformator
1. Step-Up
3. Autotransformator
Transformator jenis ini hanya terdiri dari satu lilitan yang berlanjut
secara listrik, dengan sadapan tengah. Dalam transformator ini,
sebagian lilitan primer juga merupakan lilitan sekunder. Fasa arus
dalam lilitan sekunder selalu berlawanan dengan arus primer,
sehingga untuk tarif daya yang sama lilitan sekunder bisa dibuat
dengan kawat yang lebih tipis dibandingkan transformator biasa.
Keuntungan dari autotransformator adalah ukuran fisiknya yang
kecil dan kerugian yang lebih rendah daripada jenis dua lilitan.
Tetapi transformator jenis ini tidak dapat memberikan isolasi
secara listrik antara lilitan primer dengan lilitan sekunder.
Simbol autotransformator
4. Autotransformator variabel
5. Transformator isolasi
6. Transformator pulsa
Pemeriksaan Transformator
Untuk mengetahui sebuah trafo masih bagus atau sudah rusak adalah
dengan menggunakan AVO meter. Caranya posisikan AVO meter pada
posisi Ohm meter, lalu cek lilitan primernya harus terhubung. Demikian
juga lilitan sekundernya juga harus terhubung. Sedangkan antara
lilitan primer dan skunder tidak boleh terhubung, jika terhubung maka
trafo tersebut konslet (kecuali untuk jenis trafo tertentu yang memang
didesain khusus untuk pemakaian tertentu). Begitu juga antara inti
trafo dan lilitan primer/skunder tidak boleh terhubung, jika terhubung
maka trafo tersebut akan mengalami kebocoran arus jika digunakan.
Secara fisik trafo yang bagus adalah trafo yang memiliki inti trafo yang
rata dan rapat serta jika digunakan tidak bergetar, sehingga efisiensi
dayanya bagus. Dalam penggunaannya perhatikan baik2 tegangan
kerja trafo, tiap tep-nya biasanya ditulis tegangan kerjanya misalnya
pada primernya 0V – 110V – 220V, untuk tegangan 220 volt gunakan
tep 0V dan 220V, sedangkan untuk tegangan 110 volt gunakan 0V dan
110V, jangan sampai salah atau trafo kita bakal hangus! Dan pada
skundernya misalnya 0V – 3V – 6V – 12V dsb, gunakan 0V dan
tegangan yang diperlukan. Ada juga jenis trafo yang menggunakan CT
(Center Tep) yang artinya adalah titik tengah. Contoh misalnya 12V –
CT – 12V, artinya jika kita gunakan tep CT dan 12V maka besarnya
tegangan adalah 12 volt, tapi jika kita gunakan 12V dan 12V besarnya
tegangan adalah 24 volt.
2. Kumparan Transformator
Transformator Ideal
Pada transformator ideal, tidak ada energi yang diubah menjadi bentuk
energi lain di dalam transformator sehingga daya listrik pada
kumparan skunder sama dengan daya listrik pada kumparan primer.
Atau dapat dikatakan efisiensi pada transformator ideal adalah 100
persen. untuk transformator ideal berlaku persamaan sebagai berikut :
Efisiensi Transformator
Efisiensi transformator didefinisikan sebagai perbandingan antara daya
listrik keluaran dengan daya listrik yang masuk pada transformator.
Pada transformator ideal efisiensinya 100 %, tetapi pada
kenyataannya efisiensi tranformator selalu kurang dari 100 %.hal ini
karena sebagian energi terbuang menjadi panas atau energi bunyi.
• Dengan arus listrik yang kecil maka energi yang hilang pada
kawat transmisi (energi disipasi) juga kecil.
Energi listrik atau daya listrik yang hilang pada kawat transmisi jarak
jauh dapat dihitung dengan persamaan energi dan daya listrik sebagai
berikut:
W = energi listrik (joule)
I = kuat arus listrik (ampere)
R = hambatan (ohm)
t = waktu
P = daya listrik (watt)
Contoh Soal :
Contoh cara menghitung jumlah lilitan sekunder :
Untuk menyalakan lampu 10 volt dengan tegangan listrik dari PLN 220
volt digunakan transformator step down. Jika jumlah lilitan primer
transformator 1.100 lilitan, berapakah jumlah lilitan pada kumparan
sekundernya ?
Penyelesaian :
Diketahui : Vp = 220 V
Vs = 10 V
Np = 1100 lilitan
Ditanyakan : Ns = ………… ?
Jawab :
Jadi, banyaknya lilitan sekunder adalah 50 lilitan.
Sebuah transformator step down mempunyai jumlah lilitan primer 1000 dan lilitan
sekunder 200, digunakan untuk menyalakan lampu 12 V, 48 W.
Tentukan :
Penyelesaian :
Ditanyakan :
a. Is = ……….. ?
b. Ip = ……….. ?
Jawab :
P=I.V
Penyelesaian :
Diketahui :
Ditanyakan :
a. Pp = ……….. ?
b. Ps = ……….. ?
Jawab :
Penyelesaian:
Diketahui:
P = 2 MW = 2.106 watt
R = 0,01 ohm
Ditanyakan:
Jadi, energi yang hilang di perjalanan setiap detiknya 106 watt. Nilai ini
sangat besar karena setengah dayanya akan hilang.
Jadi, energi yang hilang di perjalanan setiap detiknya hanya 0,25 watt
Contoh Soal
1. Sebuah trafo memiliki perbandingan lilitan 10 : 2 dihubungkan ke
sumber listrik 100V untuk menyalakan sebuah lampu 25 W.
Hitunglah tegangan listrik yang diserap oleh lampu dan kuat arus
yang masuk kedalam trafo
Jawab :
Diket: Np:Ns = 10 : 2
Vp = 100 V
Ps = 25 W
Dit. Vs = …
Ip = …
Jawab:
Np : Ns = Vp : Vs Pp = Ps
10 : 2 = 100 : Vs Vp . Ip = Ps
Vs = 20 V 100 . Ip = 25
Ip = 0,25 A
Diket: Np : Ns = 10:1
Vp = 100 V
Ps = 7,5W
η = 75%
Dit Ip = …
Jawab:
η = (Ps/Pp)X100 % Pp = Vp . Ip
75 % = 7,5/Pp X 100% 10 = 100 . Ip
Pp = 7,7/0,75 = 10 W
huruf E dan I
b. Koker
Koker atau rumah atau tempat mengulung kumparan primer dan
sekunder
c. Kawat email
Kawat email yang terbuat dari tembaga yang dilapiskan bahan isolasi
yang tahan panas.
Keterangan :
I2 = arus yang mengalir ke beban
E1 = tegangan gulungan primer dari PLN
E2 = tegangan gulungan sekunder
Di negara kita tegangan listrik berfrekuensi sekitar 50 sampai 60
circle/second. Oleh sebab itu untuk menghitung gulungan pervolt kita
dapat memakai rumus :
56 x 1 gulungan
Keliling besi kern untuk koker
Rumus :
gpv = f / O
Dimana
Gpv = jumlah gulung per volt
f = frekuensi listrik (50 Hz)
O = luas irisan teras diukur dengan cm2. (hasil kali dari lebar dan
tinggi tempat gulungan
Contoh 1 :
Jawab :
gpv = f / O
f = 50 Hz
O = 2,5 x 2 = 5 Cm2
gpv = 50 / 5
= 10 gulung / volt
(setiap 10 lilitan kawat berlaku untuk tegangan sebesar 1 volt)
Contoh 2 :
Jawab :
O = 2,5 x 2 = 5 cm2
gpv = 50 / 5 = 10
Contoh 3
Suatu alat memakai tenaga listrik 400 Watt dipasang pada tegangan
20 V. Berapa garis tengah kawat yang dibutuhkan untuk
menghubungkan alat tersebut ke sumber aliran?
W = 400 Watt
E = 200 Volt
I = W/E I = 400/200 I = 2 Ampere
Agar mampu dilewati arus sebesar 2 A dipakai kawat dengan ukuran
garis tengah 1 mm. Transformator jala-jala umumnya mempunyai
gulungan yang bercabang guna menyesuaikan tegangan.
Pemecahannya:
0 = 2,5 x 2 = 5 Cm2
gpv = 50/5 = 10
Digulung dulu sebanyak 1100 lilitan untuk 110 V, kemudian ujung dari
akhir gulungan disalurkan keluar sebagai cabang untuk kemudian
digulung lagi sebanyak 1100 lilitan lagi untuk tegangan 2200 V.
Demikian halnya pada gulungan sekunder: kawat digulung dulu
sebesar 66 lilitan untuk tegangan 6 V kemudian di cabang, untuk
kemudian ditambah gulungan lagi sebesar 33 lilitan buat tegangan 9
V.
Dimana :
W2 = tegangan sekunder.
E2 = tegangan sekunder.
= 1,25 X 4,5
I1 = 5,6/220
= 0,025 A = 25 mA.
Apakah bagian primer atau sekunder yang digulung terlebih dulu tidak
menjadi soal karena keduanya akan memberikan hasil yang sama.
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27 Komentar »
1. salam kenal. thank’s artikel bagus nih……………. mengenai penggulungan trafo
ada yg mau sy tanyakan mas
1.mengenai ukuran kluas teras trafo apakah ada cara untuk menentukan luasnya
( rumus bakunya).
2.jika dalam penggulungan trafo, tidak menggunakan inti ( hanya koker saja),
tentunya induksi yg di bangkitkan ke kumparan S akan berkurang, pertanyaan sy
bgmn pembuktiannya secara teoritik. mohon bantuannya karena sy berniat untuk
perancangan generator mini tanpa inti menggunakan magnet permanent.
atas perhatian dan tanggapannya sy ucapkan trimakasih
2. kelihatannya rumus gpv = f / O tidak berlaku untuk frekuensi sangat tinggi, misal
pembuatan trafo AC matic dengan inti ferit, rumusnya jadi salah semakin tinggi
frekuensi jumlah lilitan akan semakin sedikit dengan besar tegangan yang sama.
3. Pa’saya ingin belajar menggulung transformator. tempat yang bagus yang dapat
saya belajar dimana ya pa?
saya tinggal dijakarta.skalian menjadi bahan kerja praktek saya pa.
Vp = tegangan primer
f = frekuensi
n = jumlah lilitan
B = rapat fluksi
a = luas penampang kern
atau
φ Vp = 4,44.f.n.
= fluksiφ
untuk B dapat dilihat dari grafik hubungan B dan H dari sebuah inti cari nilai
yang masih linier.
Atau mencari mr .Hµ m0.µ B = H sendiri H = n.I/l
mo = permiabilitas udara
mr = permiabilitas bahan inti
jadi untuk membuat trafo inti udara silahkan otak atik mo dan mr (baca miu)
sebetulnya masih banyak untuk menurunkan rumus trafo tapi itu yang pokok
5. maaf simbolnya salah karena dari word dicopy ke sini simbolnya berubah
B=mo.mr.H
Vp=4.44.f.n.fluksi
6. komplit……….
masih seputer devices…
Komentar oleh erik | 7 Maret 2010 | Balas
8. Tolong dong, tempat saya jauh dari jangkauan PLN saya mau bikin PLTA mikro
hitungan dinamonya bagaimana ( saya butuh 2000-3000 watt. ditunggu balasanya
12. artikel bagus nih, klo boleh lengkapi dengan cara praktek membuat trafo, mulai
dari memilih kern, koker (bobin), kerta isolator, varnish dll.
terus apa bedanya trafo CT dan NCT, misalnya apakah trafo NCT dgn Vs=0-45v
sama dengan trafo CT dgn Vs=45-CT-45 juga apakah sama dengan multi voltage
spt 45-0-0-45 ?
thank you.
14. Saya berencana memberi daftar tabel gulungan trafo dari mulai luas penampang
kern, jumlah lilitan dan diameter kawat.
mudah-mudahan tidak lama lagi akan selesai.
15. berapa nilai hasil pengujian untuk trafo step down 150/20 kV 60 MVA,,,,,
tolong dibantu ya….
16. saya mau beli travo step up, waktu itu di toko ada 2 merk. kata tokonya yang
harga 160rb itu bisa keluar sktr 300W tapi yang 60rb bisa keluar sekitar 200W.
padahal amper sama 5A. sedangkan saya butuh yang keluar 700W. erus saya
harus beli yang seperti apa untuk memenuhi itu??? dan cara mengetes travo tanpa
harus di coba itu bisa tidak???
17. mohon bantuannya…ada yang mengerti tentang stacking core dan wound core
pada trafo ga…?
trus masing-masing keuntungan dan kerugian dari model itu apa ya..?thanks
20. Bos kalo mau bikin trafo untuk las, gimana rancangannya, Nwn
21. apakah bisa digunakan tafo ini jd trafo sit dwon menjadi step up?????
22. mas artikelnya keren, tapi bisa gak kita ngerancang trafo step up 220 to 280 untuk
generator 3kVA
24. ada yang tau macam2 transformator step down pada mesin las g? tolon ifonya
dum,.
jalu_cancer@yahoo.co.id
Transformator
Dari Wikipedia bahasa Indonesia, ensiklopedia bebas
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Transformator atau transformer atau trafo adalah komponen elektromagnet yang dapat
mengubah taraf suatu tegangan AC ke taraf yang lain.
Transformator step-down
• 1 Prinsip kerja
• 2 Hubungan Primer-Sekunder
• 3 Kerugian dalam transformator
• 4 Efisiensi
• 5 Jenis-jenis transformator
o 5.1 Step-Up
o 5.2 Step-Down
o 5.3 Autotransformator
o 5.4 Autotransformator variabel
o 5.5 Transformator isolasi
o 5.6 Transformator pulsa
o 5.7 Transformator tiga fasa
• 6 Lihat pula
[sunting] Prinsip kerja
Transformator bekerja berdasarkan prinsip induksi elektromagnetik. Tegangan masukan
bolak-balik yang membentangi primer menimbulkan fluks magnet yang idealnya semua
bersambung dengan lilitan sekunder. Fluks bolak-balik ini menginduksikan GGL dalam
lilitan sekunder. Jika efisiensi sempurna, semua daya pada lilitan primer akan
dilimpahkan ke lilitan sekunder.
Rumus untuk fluks magnet yang ditimbulkan lilitan primer adalah dan
[sunting] Efisiensi
Transformator step-up adalah transformator yang memiliki lilitan sekunder lebih banyak
daripada lilitan primer, sehingga berfungsi sebagai penaik tegangan. Transformator ini
biasa ditemui pada pembangkit tenaga listrik sebagai penaik tegangan yang dihasilkan
generator menjadi tegangan tinggi yang digunakan dalam transmisi jarak jauh.
[sunting] Step-Down
Transformator step-down memiliki lilitan sekunder lebih sedikit daripada lilitan primer,
sehingga berfungsi sebagai penurun tegangan. Transformator jenis ini sangat mudah
ditemui, terutama dalam adaptor AC-DC.
[sunting] Autotransformator
skema autotransformator
Transformator jenis ini hanya terdiri dari satu lilitan yang berlanjut secara listrik, dengan
sadapan tengah. Dalam transformator ini, sebagian lilitan primer juga merupakan lilitan
sekunder. Fasa arus dalam lilitan sekunder selalu berlawanan dengan arus primer,
sehingga untuk tarif daya yang sama lilitan sekunder bisa dibuat dengan kawat yang lebih
tipis dibandingkan transformator biasa. Keuntungan dari autotransformator adalah ukuran
fisiknya yang kecil dan kerugian yang lebih rendah daripada jenis dua lilitan. Tetapi
transformator jenis ini tidak dapat memberikan isolasi secara listrik antara lilitan primer
dengan lilitan sekunder.
Selain itu, autotransformator tidak dapat digunakan sebagai penaik tegangan lebih dari
beberapa kali lipat (biasanya tidak lebih dari 1,5 kali).
Transformator isolasi memiliki lilitan sekunder yang berjumlah sama dengan lilitan
primer, sehingga tegangan sekunder sama dengan tegangan primer. Tetapi pada beberapa
desain, gulungan sekunder dibuat sedikit lebih banyak untuk mengkompensasi kerugian.
Transformator seperti ini berfungsi sebagai isolasi antara dua kalang. Untuk penerapan
audio, transformator jenis ini telah banyak digantikan oleh kopling kapasitor.
Transformator tiga fasa sebenarnya adalah tiga transformator yang dihubungkan secara
khusus satu sama lain. Lilitan primer biasanya dihubungkan secara bintang (Y) dan lilitan
sekunder dihubungkan secara delta (Δ).
MENGGULUNG TRAFO
PERHITUNGAN PRAKTIS LILITAN TRAFO
Oleh: Arif Johar Taufiq
A transformer is a device that transfers electrical energy from one circuit to another through
inductively coupled conductors—the transformer's coils. A varying current in the first or
primary winding creates a varying magnetic flux in the transformer's core, and thus a varying
magnetic field through the secondary winding. This varying magnetic field induces a varying
electromotive force (EMF) or "voltage" in the secondary winding. This effect is called mutual
induction.
If a load is connected to the secondary, an electric current will flow in the secondary winding
and electrical energy will be transferred from the primary circuit through the transformer to
the load. In an ideal transformer, the induced voltage in the secondary winding (VS) is in
proportion to the primary voltage (VP), and is given by the ratio of the number of turns in the
secondary (NS) to the number of turns in the primary (NP) as follows:
By appropriate selection of the ratio of turns, a transformer thus allows an alternating current
(AC) voltage to be "stepped up" by making NS greater than NP, or "stepped down" by making NS
less than NP.In the vast majority of transformers, the windings are coils wound around a
ferromagnetic core, air-core transformers being a notable exception.
Ilmu ini adalah oleh-oleh waktu dulu kerja di PT. Riau Sakti United Plantation (PT. RSUP-
Industry) waktu dikirim untuk mempelajari kelistrikan di departemen Boiler PT. Pulau Sambu
Kuala Enok (sambu grup) dan saat mampir di departemen listriknya dan ketemu Managernya
pada saat itu di bengkel dan ada yang menggulung trafo, jadi catatan di bawah ini semoga
bermanfaat:.
Kapasitas trafo:
(Leff)2 x rugi-rugi dalam trafo = (32,5)2 x 0,64 = 676 VA
Mencari arus primer:
Arus primer = Kapasitas Trafo/Tegangan primer = 676/220 = 3,1A
Mencari arus sekunder:
Arus sekunder = Kapasitas Trafo/Tegangan sekunder = 676/24 = 28,2A
Jumlah lilitan per volt:
Jumlah lilitan per volt = Frek/Leff = 50Hz/32,5 = 1,54 lilitan/volt
SEHINGGA:
Jumlah lilitan total sisi primer:
(input 220V) = 1,54 x 220 = 339 lilit
Jumlah lilitan total sisi sekunder:
(output 24V) = 1,54 x 24 = 37 lilit
Here, three inductor coils share a common magnetic core, magnetically “coupling” or
“linking” them together. Di sini, tiga kumparan induktor berbagi inti magnetik umum,
magnetis "kopling" atau "menghubungkan" mereka bersama-sama. The relationship of
winding turn ratios and voltage ratios seen with a single pair of mutual inductors still
holds true here for multiple pairs of coils. Hubungan rasio gilirannya berliku dan rasio
tegangan dilihat dengan sepasang induktor saling tunggal masih berlaku di sini untuk
pasang beberapa koil. It is entirely possible to assemble a transformer such as the one
above (one primary winding, two secondary windings) in which one secondary winding
is a step-down and the other is a step-up. Hal ini seluruhnya memungkinkan untuk
merakit sebuah transformator seperti satu di atas (satu gulungan primer, dua belitan
sekunder) di mana satu gulungan sekunder adalah langkah-down dan yang lainnya adalah
langkah-up. In fact, this design of transformer was quite common in vacuum tube power
supply circuits, which were required to supply low voltage for the tubes' filaments
(typically 6 or 12 volts) and high voltage for the tubes' plates (several hundred volts)
from a nominal primary voltage of 110 volts AC. Bahkan, desain transformator cukup
umum di sirkuit listrik pasokan tabung vakum, yang diminta untuk menyediakan
tegangan rendah untuk 'filamen (biasanya 6 atau 12 volt) dan tegangan tinggi untuk
tabung' tuba pelat (beberapa ratus volt) dari utama tegangan nominal 110 volt AC. Not
only are voltages and currents of completely different magnitudes possible with such a
transformer, but all circuits are electrically isolated from one another. Tidak hanya
tegangan dan arus benar-benar besaran berbeda mungkin dengan seperti trafo, tapi semua
sirkuit yang elektrik terisolasi dari satu sama lain.
Photograph of multiple-winding transformer with six windings, a primary and five
secondaries. Foto multi-belitan transformator dengan enam gulungan, dan lima
sekunder primer.
The transformer in Figure above is intended to provide both high and low voltages
necessary in an electronic system using vacuum tubes. Transformator pada Gambar di
atas dimaksudkan untuk memberikan baik dan rendah tegangan tinggi yang penting
dalam suatu sistem elektronik dengan tabung vakum. Low voltage is required to power
the filaments of vacuum tubes, while high voltage is required to create the potential
difference between the plate and cathode elements of each tube. Tegangan rendah
diperlukan untuk menyalakan filamen tabung vakum, sementara tegangan tinggi
diperlukan untuk menciptakan perbedaan potensial antara elemen pelat dan katoda tabung
masing-masing. One transformer with multiple windings suffices elegantly to provide all
the necessary voltage levels from a single 115 V source. Satu transformator dengan
belitan beberapa sudah cukup elegan untuk memberikan semua level tegangan yang
diperlukan dari satu sumber tunggal 115 V. The wires for this transformer (15 of them!)
are not shown in the photograph, being hidden from view. Kabel untuk transformator (15
dari mereka!) Tidak ditampilkan dalam foto, yang tersembunyi dari pandangan.
A tap is nothing more than a wire connection made at some point on a winding between
the very ends. Sebuah keran tidak lebih dari sambungan kawat yang dibuat di beberapa
titik pada suatu lilitan antara ke ujung. Not surprisingly, the winding turn/voltage
magnitude relationship of a normal transformer holds true for all tapped segments of
windings. Tidak mengherankan, giliran berliku / hubungan besarnya tegangan dari
transformator yang normal berlaku untuk semua segmen disadap gulungan. This fact can
be exploited to produce a transformer capable of multiple ratios: (Figure below ) Hal ini
dapat dimanfaatkan untuk menghasilkan transformator yang mampu beberapa rasio:
(Gambar bawah )
A tapped secondary using a switch to select one of many possible voltages. Sebuah
menepuk sekunder menggunakan switch untuk memilih salah satu dari banyak
kemungkinan tegangan.
Carrying the concept of winding taps further, we end up with a “variable transformer,”
where a sliding contact is moved along the length of an exposed secondary winding, able
to connect with it at any point along its length. Mengusung konsep berliku keran lebih
lanjut, kami berakhir dengan sebuah "transformator variabel," di mana kontak geser
dipindahkan sepanjang suatu terkena gulungan sekunder, mampu berhubungan dengan itu
pada setiap titik sepanjang panjangnya. The effect is equivalent to having a winding tap
at every turn of the winding, and a switch with poles at every tap position: (Figure
below ) Efeknya adalah setara dengan memiliki tekan berliku di setiap pergantian
berkelok-kelok, dan sebuah saklar dengan tiang di setiap posisi tap: (Gambar bawah )
A sliding contact on the secondary continuously varies the secondary voltage. Sebuah
kontak geser pada sekunder terus bervariasi tegangan sekunder.
One consumer application of the variable transformer is in speed controls for model train
sets, especially the train sets of the 1950's and 1960's. Salah satu konsumen penerapan
transformator variabel di kontrol kecepatan untuk set model kereta api, terutama kereta
set 1950-an dan 1960-an. These transformers were essentially step-down units, the
highest voltage obtainable from the secondary winding being substantially less than the
primary voltage of 110 to 120 volts AC. Transformer ini pada dasarnya merupakan unit
step down, tegangan tertinggi diperoleh dari gulungan sekunder yang substansial kurang
dari tegangan utama AC 110 hingga 120 volt. The variable-sweep contact provided a
simple means of voltage control with little wasted power, much more efficient than
control using a variable resistor! Kontak variabel-menyapu disediakan sarana sederhana
kontrol tegangan dengan daya terbuang sedikit, jauh lebih efisien dibandingkan kontrol
menggunakan resistor variabel!
Moving-slide contacts are too impractical to be used in large industrial power transformer
designs, but multi-pole switches and winding taps are common for voltage adjustment.
Pindah-slide kontak terlalu praktis untuk digunakan dalam desain transformator tenaga
besar industri, tetapi switch multi-kutub dan berliku keran biasa digunakan untuk
penyesuaian tegangan. Adjustments need to be made periodically in power systems to
accommodate changes in loads over months or years in time, and these switching circuits
provide a convenient means. Penyesuaian perlu dilakukan secara periodik dalam sistem
kekuasaan untuk mengakomodasi perubahan beban selama berbulan-bulan atau tahun
dalam waktu, dan switching sirkuit ini menyediakan sarana yang nyaman. Typically, such
“tap switches” are not engineered to handle full-load current, but must be actuated only
when the transformer has been de-energized (no power). Biasanya, seperti "tekan switch"
tidak dirancang untuk menangani beban penuh saat ini, tetapi harus digerakkan hanya
bila transformator telah de-energized (kekuasaan).
Seeing as how we can tap any transformer winding to obtain the equivalent of several
windings (albeit with loss of electrical isolation between them), it makes sense that it
should be possible to forego electrical isolation altogether and build a transformer from a
single winding. Mengingat bagaimana kita dapat menekan setiap transformator berliku
untuk mendapatkan setara dengan beberapa gulungan (meskipun dengan hilangnya
isolasi listrik antara mereka), masuk akal bahwa itu harus mungkin untuk melepaskan
isolasi listrik sama sekali dan membangun trafo dari satu berkelok-kelok. Indeed this is
possible, and the resulting device is called an autotransformer : (Figure below ) Memang
ini mungkin, dan perangkat yang dihasilkan disebut autotransformer sebuah: (Gambar
bawah )
This autotransformer steps voltage up with a single tapped winding, saving copper,
sacrificing isolation. Tegangan langkah ini autotransformer dengan satu disadap
berkelok-kelok, tabungan tembaga, mengorbankan isolasi.
The prime advantage of an autotransformer is that the same boosting or bucking function
is obtained with only a single winding, making it cheaper and lighter to manufacture than
a regular (isolating) transformer having both primary and secondary windings.
Keuntungan utama autotransformer adalah bahwa sama meningkatkan atau bucking
fungsi diperoleh dengan hanya satu berkelok-kelok, sehingga lebih murah dan lebih
ringan untuk memproduksi dari transformator (mengisolasi) biasa yang memiliki kedua
gulungan primer dan sekunder.
Small variacs for benchtop use are popular pieces of equipment for the electronics
experimenter, being able to step household AC voltage down (or sometimes up as well)
with a wide, fine range of control by a simple twist of a knob. variacs kecil untuk
digunakan benchtop adalah potongan populer peralatan untuk eksperimen elektronik, bisa
langkah tegangan AC rumah tangga turun (atau kadang-kadang sampai juga) dengan
berbagai, macam denda kontrol oleh twist sederhana sebuah tombol.
• REVIEW: TINJAUAN:
• Transformers can be equipped with more than just a single primary and single
secondary winding pair. Transformers dapat dilengkapi dengan lebih dari hanya
satu pasang primer dan sekunder tunggal berliku. This allows for multiple step-up
and/or step-down ratios in the same device. Hal ini memungkinkan untuk
beberapa langkah-up dan / atau rasio langkah-down pada perangkat yang sama.
• Transformer windings can also be “tapped:” that is, intersected at many points to
segment a single winding into sections. belitan Transformer juga bisa "disadap:"
yang, berpotongan pada titik-titik banyak untuk segmen satu berkelok-kelok
menjadi beberapa bagian.
• Variable transformers can be made by providing a movable arm that sweeps
across the length of a winding, making contact with the winding at any point
along its length. transformer Variabel dapat dibuat dengan menyediakan lengan
bergerak yang menyapu seluruh panjang suatu berkelok-kelok, membuat kontak
dengan berliku di setiap titik sepanjang panjangnya. The winding, of course, has
to be bare (no insulation) in the area where the arm sweeps. Berkelok-kelok, tentu
saja, harus kosong (tidak ada isolasi) di daerah di mana menyapu lengan.
• An autotransformer is a single, tapped inductor coil used to step up or step down
voltage like a transformer, except without providing electrical isolation.
autotransformer adalah sebuah, tunggal mengetuk kumparan induktor digunakan
untuk meningkatkan atau turun tegangan seperti trafo, kecuali tanpa memberikan
isolasi listrik.
• A Variac is a variable autotransformer. Sebuah Variac adalah autotransformer
variabel.
Sejarah
[ edit ] Discovery [ sunting ] Penemuan
..
where mana is the magnitude of the EMF in volts and Φ B is the magnetic flux through
the circuit (in webers ). [ 3 ] adalah besarnya EMF dalam volt dan Φ B adalah fluks magnet
melalui sirkuit (dalam webers ). [3]
Faraday performed the first experiments on induction between coils of wire, including
winding a pair of coils around an iron ring, thus creating the first toroidal closed-core
transformer. [ 4 ] Faraday melakukan percobaan pertama pada induksi antara gulungan
kawat, termasuk berliku sepasang koil sekitar cincin besi, sehingga menciptakan pertama
toroidal -core transformator ditutup. [4]
The first type of transformer to see wide use was the induction coil , invented by Rev.
Nicholas Callan of Maynooth College , Ireland in 1836. Jenis pertama dari transformator
untuk melihat menggunakan lebar adalah kumparan induksi , diciptakan oleh Rev
Nicholas Callan dari Maynooth College , Irlandia pada tahun 1836. He was one of the
first researchers to realize that the more turns the secondary winding has in relation to the
primary winding, the larger is the increase in EMF. Dia adalah salah satu peneliti pertama
yang menyadari bahwa semakin mengubah gulungan sekunder telah sehubungan dengan
gulungan primer, semakin besar adalah peningkatan EMF. Induction coils evolved from
scientists' and inventors' efforts to get higher voltages from batteries. Kumparan induksi
berevolusi dari ilmuwan dan penemu 'upaya untuk mendapatkan tegangan yang lebih
tinggi dari baterai. Since batteries produce direct current (DC) rather than alternating
current (AC) , induction coils relied upon vibrating electrical contacts that regularly
interrupted the current in the primary to create the flux changes necessary for induction.
Karena baterai menghasilkan arus searah (DC) bukan bergantian) arus (AC kumparan
induksi, diandalkan bergetar kontak listrik yang secara teratur terputus arus di primer
untuk menciptakan perubahan fluks yang diperlukan untuk induksi. Between the 1830s
and the 1870s, efforts to build better induction coils, mostly by trial and error, slowly
revealed the basic principles of transformers. Antara tahun 1830-an dan 1870-an, upaya
untuk membangun kumparan induksi yang lebih baik, kebanyakan oleh trial and error,
perlahan mengungkapkan prinsip-prinsip dasar transformator.
By the 1870s, efficient generators that produced alternating current ( alternators ) were
available, and it was found that alternating current could power an induction coil directly,
without an interrupter. Pada, tahun 1870-an efisien generator yang menghasilkan
alternating current ( alternator ) yang tersedia, dan ditemukan bahwa arus listrik dapat
bolak suatu kumparan induksi secara langsung, tanpa interrupter sebuah. In 1876,
Russian engineer Pavel Yablochkov invented a lighting system based on a set of
induction coils where the primary windings were connected to a source of alternating
current and the secondary windings could be connected to several "electric candles" (arc
lamps) of his own design. [ 5 ] [ 6 ] The coils Yablochkov employed functioned essentially
as transformers. [ 5 ] Pada tahun 1876, Rusia insinyur Pavel Yablochkov menciptakan
sebuah sistem pencahayaan berdasarkan set kumparan induksi dimana gulungan primer
dihubungkan ke sumber arus bolak balik dan gulungan sekunder bisa dihubungkan ke
beberapa "lilin listrik" (lampu busur) sendiri desain. [5] [6] Kumparan Yablochkov
dipekerjakan pada dasarnya berfungsi sebagai transformer. [5]
In 1878, the Ganz Company in Hungary began manufacturing equipment for electric
lighting and, by 1883, had installed over fifty systems in Austria-Hungary . Pada tahun
1878, yang Ganz Perusahaan di Hungaria mulai manufaktur peralatan untuk penerangan
listrik dan, oleh 1883, telah diinstal di atas sistem lima puluh di Austria-Hongaria . Their
systems used alternating current exclusively and included those comprising both arc and
incandescent lamps, along with generators and other equipment. [ 7 ] sistem mereka
digunakan arus bolak-balik secara eksklusif dan termasuk orang-orang baik yang terdiri
dari busur dan pijar lampu, bersama dengan generator dan peralatan lainnya. [7]
Lucien Gaulard and John Dixon Gibbs first exhibited a device with an open iron core
called a "secondary generator" in London in 1882, then sold the idea to the Westinghouse
company in the United States . [ 8 ] They also exhibited the invention in Turin, Italy in
1884, where it was adopted for an electric lighting system. [ 9 ] However, the efficiency of
their open-core bipolar apparatus remained very low. [ 10 ] Lucien Gaulard dan John Dixon
Gibbs pertama dipamerkan perangkat dengan inti besi terbuka yang disebut sebagai
"generator sekunder" di London tahun 1882, kemudian dijual ide ini ke Westinghouse
perusahaan di Amerika Serikat . [8] Mereka juga dipamerkan penemuan di Turin, Italia
pada tahun 1884, di mana ia diadopsi untuk sistem penerangan listrik. [9] Namun, efisiensi
aparatusnya terbuka-bipolar inti tetap sangat rendah. [10]
Induction coils with open magnetic circuits are inefficient for transfer of power to loads .
Induksi koil dengan sirkuit magnetik terbuka tidak efisien untuk transfer kekuatan untuk
beban . Until about 1880, the paradigm for AC power transmission from a high voltage
supply to a low voltage load was a series circuit. Sampai sekitar tahun 1880, paradigma
untuk transmisi listrik AC dari pasokan tegangan tinggi menjadi tegangan rendah yang
beban adalah sebuah rangkaian seri. Open-core transformers with a ratio near 1:1 were
connected with their primaries in series to allow use of a high voltage for transmission
while presenting a low voltage to the lamps. Buka-core transformator dengan rasio dekat
01:01 dihubungkan dengan primary mereka dalam seri untuk memungkinkan penggunaan
tegangan tinggi untuk transmisi sementara presentasi tegangan rendah ke lampu. The
inherent flaw in this method was that turning off a single lamp affected the voltage
supplied to all others on the same circuit. Cacat yang melekat dalam metode ini adalah
bahwa mematikan lampu tunggal terkena tegangan yang diberikan kepada semua orang
lain di sirkuit yang sama. Many adjustable transformer designs were introduced to
compensate for this problematic characteristic of the series circuit, including those
employing methods of adjusting the core or bypassing the magnetic flux around part of a
coil. [ 11 ] Banyak desain trafo disesuaikan diperkenalkan untuk mengkompensasi hal ini
karakteristik bermasalah dari rangkaian seri, termasuk metode menggunakan penyesuaian
inti atau melewati fluks magnet di sekitar bagian dari sebuah kumparan. [11]
Efficient, practical transformer designs did not appear until the 1880s, but within a
decade the transformer would be instrumental in the " War of Currents ", and in seeing
AC distribution systems triumph over their DC counterparts, a position in which they
have remained dominant ever since. [ 12 ] Efisien, desain transformator praktis tidak
muncul sampai tahun 1880-an, tetapi dalam satu dekade transformator akan menjadi
instrumen dalam " Perang Arus ", dan dalam melihat AC sistem distribusi kemenangan
atas DC rekan-rekan mereka, posisi di mana mereka tetap dominan pernah sejak. [12]
Drawing of Ganz Company's 1885 prototype. Gambar Ganz 1885 prototipe Perusahaan.
Capacity: 1400 VA, frequency: 40 Hz, voltage ratio: 120/72 V Kapasitas: 1400 VA,
frekuensi: 40 Hz, rasio tegangan: V 120/72
In the autumn of 1884, [ 14 ] Ganz Company engineers Károly Zipernowsky , Ottó Bláthy
and Miksa Déri had determined that open-core devices were impracticable, as they were
incapable of reliably regulating voltage. Pada musim gugur 1884, [14] Ganz insinyur
Perusahaan Károly Zipernowsky , Otto Bláthy dan Miksa Deri telah menetapkan bahwa
terbuka-inti perangkat yang praktis, karena mereka mampu mengatur tegangan andal. In
their joint patent application for the "ZBD" transformers, they described two designs with
closed magnetic circuits: the "closed-core" and "shell-core" transformers. Dalam aplikasi
paten bersama mereka untuk "ZBD" transformer, mereka dijelaskan dua desain dengan
sirkuit magnet tertutup: "tertutup-core" dan "shell-core" transformator. In the closed-core,
the primary and secondary windings were wound around a closed iron ring; in the shell-
core, the windings were passed through the iron core. Dalam inti-tertutup, dan sekunder
gulungan primer luka di sekitar cincin besi tertutup, dalam inti-shell, gulungan yang
melewati inti besi. In both designs, the magnetic flux linking the primary and secondary
windings traveled almost entirely within the iron core, with no intentional path through
air. Dalam kedua desain, fluks magnetik menghubungkan gulungan primer dan sekunder
melakukan perjalanan hampir seluruhnya dalam inti besi, dengan tidak ada jalan yang
disengaja melalui udara. The new ZBD transformers reached 98 percent efficiency,
which was 3.4 times higher than the open core bipolar devices of Gaulard and Gibs. [ 15 ]
When they employed it in parallel connected electric distribution systems , closed-core
transformers finally made it technically and economically feasible to provide electric
power for lighting in homes, businesses and public spaces. [ 16 ] [ 17 ] Bláthy had suggested
the use of closed-cores, Zipernowsky the use of shunt connections , and Déri had
performed the experiments; [ 18 ] Bláthy also discovered the transformer formula, Vs/Vp =
Ns/Np. [ citation needed ] The vast majority of transformers in use today rely on the basic
principles discovered by the three engineers. The ZBD baru transformer efisiensi
mencapai 98 persen, yang 3,4 kali lebih tinggi dari bipolar inti perangkat terbuka Gaulard
dan Gibs. [15] Ketika mereka dipekerjakan di paralel dihubungkan sistem distribusi listrik ,
inti transformator tertutup akhirnya berhasil teknis dan ekonomis menyediakan listrik
untuk daya penerangan di rumah, bisnis dan masyarakat. ruang untuk [16] [17] Bláthy telah
menyarankan penggunaan tertutup-core, Zipernowsky penggunaan koneksi shunt , dan
Deri telah melakukan percobaan; [18] Bláthy juga menemukan rumus transformator, Vs /
Vp = Ns / Np. [ rujukan? ] Sebagian besar dari transformator yang digunakan saat ini
bergantung pada prinsip-prinsip dasar yang ditemukan oleh tiga insinyur. They also
reportedly popularized the word "transformer" to describe a device for altering the EMF
of an electric current, [ 16 ] [ 19 ] although the term had already been in use by 1882. [ 20 ] [ 21 ]
In 1886, the Ganz Company installed the world's first power station that used AC
generators to power a parallel-connected common electrical network, the steam-powered
Rome - Cerchi power plant. [ 22 ] Mereka juga dilaporkan mempopulerkan kata
"transformator" untuk menggambarkan perangkat untuk mengubah EMF dari sebuah arus
listrik, [16] [19] meskipun istilah tersebut telah digunakan oleh 1882. [20] [21] Pada tahun 1886,
yang Ganz Perusahaan pertama di dunia dipasang di pembangkit listrik yang digunakan
AC generator untuk tenaga-tersambung umum jaringan listrik paralel, uap bertenaga
Roma - Cerchi . pembangkit listrik [22]
Stanley's 1886 design for adjustable gap open-core induction coils [ 23 ] 1886 Stanley
desain untuk-buka inti kumparan induksi kesenjangan disesuaikan [23]
Although George Westinghouse had bought Gaulard and Gibbs' patents in 1885, the
Edison Electric Light Company held an option on the US rights for the ZBD
transformers, requiring Westinghouse to pursue alternative designs on the same
principles. Meskipun George Westinghouse membeli dan Gibbs 'paten Gaulard pada
1885, Edison Electric Light Company mengadakan opsi di AS hak untuk transformator
ZBD, membutuhkan Westinghouse untuk mengejar alternatif desain pada prinsip-prinsip
yang sama. He assigned to William Stanley the task of developing a device for
commercial use in United States. [ 24 ] Stanley's first patented design was for induction
coils with single cores of soft iron and adjustable gaps to regulate the EMF present in the
secondary winding. Dia ditugaskan untuk William Stanley tugas mengembangkan
perangkat untuk penggunaan komersial di Amerika Serikat. [24] dipatenkan desain pertama
Stanley adalah untuk kumparan induksi dengan core tunggal besi lunak dan kesenjangan
disesuaikan untuk mengatur EMF hadir dalam gulungan sekunder. (See drawing at left.)
[ 23 ]
This design was first used commercially in the US in 1886. [ 12 ] But Westinghouse
soon had his team working on a design whose core comprised a stack of thin "E-shaped"
iron plates, separated individually or in pairs by thin sheets of paper or other insulating
material. (Lihat gambar di sebelah kiri.) [23] Rancangan ini pertama kali digunakan secara
komersial di Amerika Serikat pada 1886. [12] Tetapi Westinghouse segera memiliki
timnya bekerja pada sebuah desain yang inti terdiri setumpuk tipis "E-berbentuk" pelat
besi, terpisah secara individu atau berpasangan dengan lembaran tipis dari kertas atau
bahan insulasi lainnya. Prewound copper coils could then be slid into place, and straight
iron plates laid in to create a closed magnetic circuit. kumparan tembaga Prewound
kemudian bisa meluncur ke tempatnya, dan besi pelat diletakkan lurus untuk membuat
sirkuit magnet tertutup. Westinghouse applied for a patent for the new design in
December 1886; it was granted in July 1887. [ 18 ] [ 25 ] Westinghouse mengajukan
permohonan paten untuk desain baru pada Desember 1886, telah diberikan pada bulan
Juli 1887. Itu [18] [25]
Audio frequency transformers (" repeating coils ") were used by early experimenters in
the development of the telephone . [ citation needed ] frekuensi Audio transformer (" gulungan
mengulang ") digunakan oleh peneliti awal perkembangan telepon . [ rujukan? ]
An ideal transformer is shown in the adjacent figure. Sebuah trafo ideal ditunjukkan pada
gambar yang berdekatan. Current passing through the primary coil creates a magnetic
field . melewati saat melalui kumparan primer menciptakan medan magnet . The primary
and secondary coils are wrapped around a core of very high magnetic permeability , such
as iron , so that most of the magnetic flux passes through both the primary and secondary
coils. Dan sekunder kumparan primer dibungkus sekitar inti yang sangat tinggi
permeabilitas magnetik , seperti besi , sehingga sebagian besar fluks magnet melewati
baik kumparan primer dan sekunder.
The voltage induced across the secondary coil may be calculated from Faraday's law of
induction , which states that: Tegangan induksi di kumparan sekunder dapat dihitung dari
Teman-hukum induksi Faraday , yang menyatakan bahwa:
where V s is the instantaneous voltage , N s is the number of turns in the secondary coil
and Φ is the magnetic flux through one turn of the coil. dimana V s adalah seketika
tegangan , N s adalah jumlah belitan dalam kumparan sekunder dan Φ adalah fluks
magnet melalui satu pergantian koil. If the turns of the coil are oriented perpendicular to
the magnetic field lines, the flux is the product of the magnetic flux density B and the
area A through which it cuts. Jika ternyata dari koil berorientasi tegak lurus dengan garis
medan magnet, fluks adalah produk dari kerapatan fluks magnet B dan daerah A sampai
yang luka. The area is constant, being equal to the cross-sectional area of the transformer
core, whereas the magnetic field varies with time according to the excitation of the
primary. Daerah ini konstan, yang sama dengan luas penampang inti transformator,
sedangkan medan magnet bervariasi dengan waktu sesuai dengan eksitasi primer. Since
the same magnetic flux passes through both the primary and secondary coils in an ideal
transformer, [ 29 ] the instantaneous voltage across the primary winding equals Karena
fluks magnet yang sama melewati baik kumparan primer dan sekunder dalam sebuah
transformator ideal, [29] tegangan sesaat di gulungan primer sama
Taking the ratio of the two equations for V s and V p gives the basic equation [ 30 ] for
stepping up or stepping down the voltage Mengambil rasio dari dua persamaan untuk s V
dan p V memberikan persamaan dasar [30] untuk melangkah ke atas atau mengundurkan
diri tegangan
N p / N s is known as the turns ratio , and is the primary functional characteristic of any
transformer. N p / N s dikenal sebagai rasio berubah, dan merupakan karakteristik
fungsional utama dari transformator apapun. In the case of step-up transformers, this may
sometimes be stated as the reciprocal, N s / N p . Turns ratio is commonly expressed as an
irreducible fraction or ratio: for example, a transformer with primary and secondary
windings of, respectively, 100 and 150 turns is said to have a turns ratio of 2:3 rather than
0.667 or 100:150. kasus meningkatkan transformer,-ini mungkin kadang-kadang
dinyatakan sebagai timbal balik s N /, N. p Dalam Ternyata rasio biasanya dinyatakan
sebagai fraksi tak tereduksi atau rasio: misalnya, dengan dan sekunder transformator
gulungan utama, masing-masing, 100 dan 150 ternyata dikatakan memiliki perbandingan
2:03 ternyata daripada 0,667 atau 100:150.
The ideal transformer as a circuit element Transformator ideal sebagai unsur rangkaian
If the secondary coil is attached to a load that allows current to flow, electrical power is
transmitted from the primary circuit to the secondary circuit. Jika kumparan sekunder
menempel pada beban yang memungkinkan untuk saat ini mengalir, daya listrik yang
ditransmisikan dari rangkaian primer ke rangkaian sekunder. Ideally, the transformer is
perfectly efficient; all the incoming energy is transformed from the primary circuit to the
magnetic field and into the secondary circuit. Idealnya, transformator adalah sempurna
efisien; semua energi masuk berubah dari rangkaian primer ke medan magnet dan masuk
ke rangkaian sekunder. If this condition is met, the incoming electric power must equal
the outgoing power: Jika kondisi ini dipenuhi, masuk tenaga listrik harus sama dengan
daya keluar:
If the voltage is increased, then the current is decreased by the same factor. Jika tegangan
dinaikkan, maka saat ini dikurangi dengan faktor yang sama. The impedance in one
circuit is transformed by the square of the turns ratio. [ 29 ] For example, if an impedance Z
s is attached across the terminals of the secondary coil, it appears to the primary circuit to
have an impedance of ( N p / N s ) 2 Z s . Impedansi dalam satu rangkaian
ditransformasikan oleh kuadrat dari rasio berubah. [29] Sebagai contoh, jika sebuah
impedansi Z s terpasang di seluruh terminal kumparan sekunder, tampaknya rangkaian
utama untuk memiliki impedansi (p N / N s) 2 Z s. This relationship is reciprocal, so that the
impedance Z p of the primary circuit appears to the secondary to be ( N s / N p ) 2 Z p .
Hubungan ini timbal balik, sehingga Z p impedansi dari rangkaian utama muncul di
sekunder untuk menjadi (N s / N p) 2 Z p.
The simplified description above neglects several practical factors, in particular the
primary current required to establish a magnetic field in the core, and the contribution to
the field due to current in the secondary circuit. Gambaran sederhana tersebut di atas
mengabaikan beberapa faktor praktis, terutama utama saat ini diperlukan untuk
membentuk medan magnet di inti, dan kontribusi ke lapangan karena saat ini di sirkuit
sekunder.
Models of an ideal transformer typically assume a core of negligible reluctance with two
windings of zero resistance . [ 31 ] When a voltage is applied to the primary winding, a
small current flows, driving flux around the magnetic circuit of the core. [ 31 ] The current
required to create the flux is termed the magnetizing current ; since the ideal core has
been assumed to have near-zero reluctance, the magnetizing current is negligible,
although still required to create the magnetic field. Model sebuah trafo ideal biasanya
mengasumsikan inti diabaikan keengganan dengan dua gulungan dari nol perlawanan . [31]
Ketika tegangan diterapkan pada gulungan primer, mengalir arus yang kecil, mengemudi
fluks sekitar sirkuit magnetik inti. [31] arus yang dibutuhkan untuk menciptakan fluks
disebut sebagai magnetizing saat ini, sejak inti yang ideal ini dianggap telah memiliki
hampir nol keengganan, arus magnet dapat diabaikan, walaupun masih diperlukan untuk
menciptakan medan magnet.
The changing magnetic field induces an electromotive force (EMF) across each winding.
[ 32 ]
Since the ideal windings have no impedance, they have no associated voltage drop,
and so the voltages V P and V S measured at the terminals of the transformer, are equal to
the corresponding EMFs. Medan magnet yang berubah menginduksi sebuah gaya gerak
listrik (EMF) di setiap berliku. [32] Karena gulungan yang ideal memiliki impedansi tidak,
mereka tidak terkait drop tegangan, sehingga tegangan V P dan V S diukur pada terminal
transformator, adalah sama dengan EMFs yang sesuai. The primary EMF, acting as it
does in opposition to the primary voltage, is sometimes termed the " back EMF ". [ 33 ]
This is due to Lenz's law which states that the induction of EMF would always be such
that it will oppose development of any such change in magnetic field. EMF utama,
bertindak sebagai itu bertentangan dengan tegangan primer, kadang-kadang disebut
sebagai " back EMF ". [33] Hal ini disebabkan 's hukum Lenz yang menyatakan bahwa
induksi EMF akan selalu sedemikian rupa sehingga akan menentang pengembangan
perubahan tersebut dalam medan magnet.
[ edit ] Practical considerations [ sunting ]
Pertimbangan praktis
[ edit ] Leakage flux [ sunting ] fluks Kebocoran
The ideal transformer model assumes that all flux generated by the primary winding links
all the turns of every winding, including itself. Model trafo ideal mengasumsikan bahwa
fluks semua link yang dihasilkan oleh lilitan primer semua berubah setiap berkelok-
kelok, termasuk dirinya sendiri. In practice, some flux traverses paths that take it outside
the windings. [ 34 ] Such flux is termed leakage flux , and results in leakage inductance in
series with the mutually coupled transformer windings. [ 33 ] Leakage results in energy
being alternately stored in and discharged from the magnetic fields with each cycle of the
power supply. Dalam prakteknya, fluks beberapa melintasi jalur yang mengambil di luar
gulungan. [34] fluks tersebut disebut fluks kebocoran, dan hasil dalam induktansi
kebocoran pada seri dengan gulungan trafo digabungkan bersama. [33] Kebocoran
menghasilkan energi yang bergantian dan disimpan dalam habis dari medan magnet
dengan masing-masing siklus power supply. It is not directly a power loss (see "Stray
losses" below), but results in inferior voltage regulation , causing the secondary voltage
to fail to be directly proportional to the primary, particularly under heavy load. [ 34 ]
Transformers are therefore normally designed to have very low leakage inductance . Hal
ini tidak langsung kehilangan daya (lihat "kerugian Stray" di bawah), tetapi hasil dalam
inferior pengaturan tegangan , tegangan sekunder menyebabkan gagal berbanding lurus
dengan utama, khususnya di bawah beban berat. [34] Transformers Oleh karena itu
biasanya dirancang untuk memiliki sangat rendah inductance kebocoran .
However, in some applications, leakage can be a desirable property, and long magnetic
paths, air gaps, or magnetic bypass shunts may be deliberately introduced to a
transformer's design to limit the short-circuit current it will supply. [ 33 ] Leaky
transformers may be used to supply loads that exhibit negative resistance , such as
electric arcs , mercury vapor lamps , and neon signs ; or for safely handling loads that
become periodically short-circuited such as electric arc welders . [ 35 ] Namun, dalam
beberapa aplikasi, kebocoran dapat menjadi properti yang diinginkan, dan jalur magnetik
panjang, kesenjangan udara, atau pirau bypass magnetik mungkin sengaja diperkenalkan
untuk transformator's merancang untuk membatasi hubungan arus pendek arus itu akan
memasok. [33] Leaky transformer mungkin digunakan untuk mensuplai beban yang
menunjukkan negatif perlawanan , seperti busur listrik , lampu uap merkuri , dan tanda-
tanda neon , atau untuk menangani beban yang aman menjadi berkala-pendek seperti
tukang las busur listrik . [35]
Air gaps are also used to keep a transformer from saturating, especially audio-frequency
transformers in circuits that have a direct current flowing through the windings. [ citation
needed ]
Kesenjangan udara juga digunakan untuk menjaga transformator dari menjenuhkan,
audio-frekuensi transformator khususnya di sirkuit yang memiliki arus searah yang
mengalir melalui gulungan. [ rujukan? ]
Leakage inductance is also helpful when transformers are operated in parallel. Kebocoran
induktansi juga membantu pada saat trafo beroperasi secara paralel. It can be shown that
if the "per-unit" inductance of two transformers is the same (a typical value is 5%), they
will automatically split power "correctly" (eg 500 kVA unit in parallel with 1,000 kVA
unit, the larger one will carry twice the current). [ citation needed ] Hal ini dapat menunjukkan
bahwa jika "per unit" induktansi dari dua transformer adalah sama (nilai tipikal adalah
5%), mereka akan secara otomatis membagi kekuatan "benar" (misalnya 500 unit kVA
secara paralel dengan 1.000 unit kVA, semakin besar satu akan membawa dua kali saat
ini). [ rujukan? ]
If the flux in the core is purely sinusoidal , the relationship for either winding between its
rms voltage E rms of the winding , and the supply frequency f , number of turns N , core
cross-sectional area a and peak magnetic flux density B is given by the universal EMF
equation: [ 31 ] Jika fluks dalam teras adalah murni sinusoidal , hubungan baik untuk
berliku antara perusahaan rms rms E tegangan dari lilitan, dan frekuensi pasokan f, jumlah
putaran N, luas penampang inti dan puncak kerapatan fluks magnet B diberikan dengan
persamaan EMF universal: [31]
If the flux does not contain even harmonics the following equation can be used for half-
cycle average voltage E avg of any waveshape: Jika fluks tidak berisi bahkan harmonik
persamaan berikut dapat digunakan untuk siklus rata-rata tegangan E-setengah avg dari
setiap bentuk gelombang:
The time-derivative term in Faraday's Law shows that the flux in the core is the integral
with respect to time of the applied voltage. [ 36 ] Hypothetically an ideal transformer would
work with direct-current excitation, with the core flux increasing linearly with time. [ 37 ]
In practice, the flux would rise to the point where magnetic saturation of the core occurs,
causing a huge increase in the magnetizing current and overheating the transformer. The-
derivatif jangka waktu di Teman Hukum Faraday menunjukkan bahwa fluks dalam teras
adalah integral terhadap waktu dari tegangan yang diterapkan. [36] hipotesis transformator
ideal akan bekerja dengan arus eksitasi langsung, dengan fluks inti meningkat secara
linear dengan waktu . [37] Dalam prakteknya, fluks akan naik ke titik di mana jenuh
magnetik inti terjadi, menyebabkan peningkatan yang sangat besar dalam arus dan
transformator magnetizing overheating. All practical transformers must therefore operate
with alternating (or pulsed) current. [ 37 ] Semua transformer praktis sehingga harus
beroperasi dengan bergantian (atau berdenyut) saat ini. [37]
Operation of a transformer at its designed voltage but at a higher frequency than intended
will lead to reduced magnetizing current; at lower frequency, the magnetizing current
will increase. Pengoperasian transformator pada tegangan yang dirancang tetapi pada
frekuensi yang lebih tinggi daripada yang dimaksudkan akan mengakibatkan berkurang
magnetizing berjalan; pada frekuensi yang lebih rendah, magnetizing saat ini akan
meningkat. Operation of a transformer at other than its design frequency may require
assessment of voltages, losses, and cooling to establish if safe operation is practical.
Pengoperasian transformator di selain frekuensi desain mungkin memerlukan penilaian
tegangan, kerugian, dan pendinginan untuk menentukan apakah operasi yang aman
praktis. For example, transformers may need to be equipped with "volts per hertz" over-
excitation relays to protect the transformer from overvoltage at higher than rated
frequency. Sebagai contoh, transformer mungkin perlu dilengkapi dengan "volt hertz per"
over-eksitasi relay untuk melindungi transformator dari tegangan lebih pada lebih tinggi
dari frekuensi pengenal.
One example of state-of-the-art design is those transformers used for electric multiple
unit high speed trains , particularly those required to operate across the borders of
countries using different standards of electrification. Salah satu contoh negara-dari-
desain-art adalah mereka transformator digunakan untuk listrik beberapa unit kereta api
berkecepatan tinggi , terutama yang dibutuhkan untuk beroperasi di perbatasan negara
dengan menggunakan standar yang berbeda elektrifikasi. The position of such
transformers is restricted to being hung below the passenger compartment. Posisi
transformer tersebut dibatasi untuk digantung di bawah kompartemen penumpang. They
have to function at different frequencies (down to 16.7 Hz) and voltages (up to 25 kV)
whilst handling the enhanced power requirements needed for operating the trains at high
speed. Mereka harus berfungsi pada frekuensi yang berbeda (turun ke 16,7 Hz) dan
tegangan (hingga 25 kV) sedangkan menangani kebutuhan listrik yang disempurnakan
yang dibutuhkan untuk mengoperasikan kereta api dengan kecepatan tinggi.
An ideal transformer would have no energy losses, and would be 100% efficient. Sebuah
trafo ideal tidak akan memiliki kehilangan energi, dan akan 100% efisien. In practical
transformers energy is dissipated in the windings, core, and surrounding structures.
Dalam transformer praktis energi didisipasikan dalam gulungan, inti, dan struktur
sekitarnya. Larger transformers are generally more efficient, and those rated for
electricity distribution usually perform better than 98%. [ 39 ] transformator yang lebih
besar umumnya lebih efisien, dan mereka dinilai untuk distribusi listrik biasanya
melakukan lebih baik dari 98%. [39]
Transformer losses are divided into losses in the windings, termed copper loss , and those
in the magnetic circuit, termed iron loss . Transformer kerugian dibagi menjadi kerugian
dalam gulungan, disebut rugi tembaga , dan mereka di sirkuit magnetik, disebut rugi
besi . Losses in the transformer arise from: Kerugian di trafo timbul dari:
It is common in transformer schematic symbols for there to be a dot at the end of each
coil within a transformer, particularly for transformers with multiple primary and
secondary windings. Hal ini sering terjadi pada simbol skematik trafo untuk itu menjadi
sebuah titik pada akhir setiap kumparan dalam trafo, terutama untuk transformator
dengan belitan primer dan sekunder beberapa. The dots indicate the direction of each
winding relative to the others. Titik menunjukkan arah relatif tiap berliku yang lain.
Voltages at the dot end of each winding are in phase; current flowing into the dot end of a
primary coil will result in current flowing out of the dot end of a secondary coil.
Tegangan pada titik akhir setiap lilitan berada dalam fase; arus yang mengalir ke titik
akhir sebuah kumparan primer akan mengakibatkan arus yang mengalir keluar dari titik
akhir kumparan sekunder.
Since I started in electronics, as a 12 year old boy, I have always wound my own
transformers. Sejak saya mulai dalam elektronik, sebagai anak laki-laki berusia 12 tahun,
saya selalu luka transformer saya sendiri. I started using the basic, but useful instructions
provided in The Radio Amateur's Handbook of the time, and later I came to better
understand how transformers work, which enabled me to optimize a given transformer
for the intended application. Saya mulai menggunakan dasar, tetapi instruksi bermanfaat
yang tersedia di Buku Pegangan Amatir Radio tentang waktu, dan kemudian saya datang
untuk lebih memahami bagaimana transformer kerja, yang memungkinkan saya untuk
mengoptimalkan transformator diberikan untuk aplikasi yang dimaksud.
Following a request by many readers of my web site, I've added this page, which is
complementary to the previously published Transformers and coils . Setelah permintaan
banyak pembaca dari situs web saya, saya telah menambahkan halaman ini, yang
merupakan pelengkap sebelumnya diterbitkan Transformers dan koil . You should first
read (and understand!) that page, before trying to design any transformer. Anda harus
terlebih dahulu membaca (dan mengerti!) Halaman tersebut, sebelum mencoba untuk
merancang transformator apapun. Then come to this more practically-oriented page, to
learn some tricks and hints about the design process, and about hands-on winding.
Kemudian datang ke halaman ini lebih berorientasi praktis, untuk mempelajari beberapa
trik dan petunjuk tentang proses desain, dan tentang tangan-on berliku.
This page addresses mainly single-phase power transformers in the power range from
about 1 watt to 10,000 watts, operating at line frequencies, but much of what's described
here can be applied to a wide range of other transformers too. Halaman ini terutama
alamat transformer satu fasa listrik dalam kisaran daya dari sekitar 1 watt sampai 10.000
watt, beroperasi pada frekuensi line, tapi banyak dari apa yang dijelaskan di sini dapat
diterapkan untuk berbagai macam transformator lain juga.
The photo here shows several stacks of iron EI laminations, two coils of wire (with
cardboard protecting the wire from damage), one roll of thick, stiff Pressspan, another
roll of NMN laminate (we will soon see what that is), two small bundles of spaghetti for
wire protection, and a can of transformer varnish. Foto ini menunjukkan beberapa
tumpukan laminasi EI besi, dua kumparan dari kawat (kawat dengan karton melindungi
dari kerusakan), salah satu gulungan tebal, Pressspan kaku, gulungan lain NMN laminasi
(kita akan segera melihat apa itu), dua kecil bundel spaghetti untuk perlindungan kawat,
dan sekaleng pernis transformator. Add to this some glue, cotton straps, ropes, adhesive
tape, terminals, bolts, angle iron, and other small material, and that's it. Tambahkan ke ini
beberapa lem, tali kapas, tali, pita perekat, terminal, baut, besi sudut, dan bahan kecil
lainnya, dan hanya itu.
All these materials are sold by companies specializing in transformers and parts for
transformers. Semua material ini dijual oleh perusahaan-perusahaan yang
mengkhususkan diri dalam transformator dan komponen untuk transformer. Enameled
wire is also sold by many other distributors, but is usually cheapest at the places that sell
it together with the other materials. kawat berenamel juga dijual oleh distributor lain,
tetapi biasanya termurah di tempat yang menjualnya bersama-sama dengan bahan lain.
You will have to dig into the phone book or some other directory to find these
companies, since they don't usually have a shiny nice store in the downtown shopping
mall! Anda harus menggali ke dalam buku telepon atau direktori lain untuk menemukan
perusahaan-perusahaan, karena mereka biasanya tidak memiliki toko bagus mengkilap di
pusat perbelanjaan pusat kota!
Transformer iron
is an alloy of iron
with silicon and
some other minor
components.
Transformer besi
merupakan
paduan besi
dengan silikon dan
beberapa
komponen kecil
lainnya. It's
characterized by a
relatively high
permeability, very
high saturation
flux density,
relatively low
hysteresis loss,
and relatively high specific resistance. Ini ditandai dengan permeabilitas relatif tinggi,
sangat tinggi saturasi densitas fluks, relatif rugi histeresis rendah, dan ketahanan tertentu
relatif tinggi. This latter factor, along with the practice of using the material in thin,
insulated sheets, reduces the power losses produced by eddy currents. Faktor terakhir,
bersama dengan praktik penggunaan bahan dalam tipis, lembaran terisolasi, mengurangi
kerugian daya yang dihasilkan oleh arus eddy.
The most common shape of these sheets is shown at right. Bentuk yang paling umum dari
lembaran ini ditampilkan di kanan. It's the classic "economy EI" shape. Ini adalah klasik
"ekonomi EI" bentuk. Why it's called EI should be pretty obvious when looking at the
photo! Mengapa disebut EI harus cukup jelas ketika melihat foto! But the explanation for
"economy" might be a bit more elusive: It's because at the exact proportions shown in the
photo, the I's are nothing else than the cutouts to make the windows in the E's, when two
E's are cut facing each other! Tetapi penjelasan untuk "ekonomi" mungkin sedikit lebih
sulit: Itu karena pada proporsi yang tepat ditampilkan dalam foto, saya adalah tidak lain
dari potongan untuk membuat jendela di E, ketika dua E dipotong saling berhadapan!
This allows stamping E's and I's out of a large steel sheet, without any wasting of
material, except for the little round bits cut out of the bolt holes. Hal ini memungkinkan
stamping E dan aku keluar dari pelat baja yang besar, tanpa membuang-buang bahan,
kecuali untuk bit dipotong bulat kecil keluar dari lubang baut. By the way, small
laminations often don't have such bolt holes, and such cores are held together by clamps
instead of bolts, or even welded. By the way, laminasi kecil sering tidak memiliki lubang
baut tersebut, dan inti tersebut disatukan oleh jepitan bukan baut, atau bahkan dilas.
The lamination in the photo is a large one, as the comparison with my hand shows. The
laminasi dalam foto adalah satu besar, sebagai perbandingan dengan menunjukkan tangan
saya. It's an E80 (the center leg is 80mm wide), typically used for transformers in the 3 to
10 kilowatt range! Ini E80 sebuah (pusat kaki 80mm lebar), biasanya digunakan untuk
transformator dalam kisaran 3 sampai 10 kilowatt!
In any EI lamination you are likely to encounter, the center leg is twice as wide as each of
the other parts. Dalam setiap laminasi EI Anda mungkin menghadapi, pusat kaki dua kali
selebar masing-masing bagian lain. This is because the entire magnetic flux has to go
through the center leg, but then splits up, with one half of the flux returning through each
of the side legs. Hal ini karena fluks magnet seluruh harus melalui kaki pusat, tetapi
kemudian pecah, dengan satu setengah dari fluks kembali melalui masing-masing sisi
kaki. If you ever come across a lamination that has all three legs of the same width, then
you are looking at a lamination intended for three phase transformers! Jika Anda pernah
datang di sebuah laminasi yang memiliki semua tiga kaki lebar yang sama, maka Anda
sedang melihat laminasi dimaksudkan untuk tiga transformator fasa!
Such an economy EI lamination like shown here has completely fixed proportions,
beyond the rule above, that stem from the need to cut the I out of the winding window of
two E's facing each other: If the center leg is 2 units wide, then the window is 1 x 3 units,
the total E is 6 x 4 units, the I is 1 x 6 units, and so on. Seperti ekonomi EI laminasi
seperti proporsi sini telah sepenuhnya tetap menunjukkan, di luar aturan di atas, yang
berasal dari kebutuhan untuk memotong saya keluar dari jendela berliku dari dua E saling
berhadapan: Jika kaki pusat adalah 2 unit lebar, maka jendela adalah 1 x 3 unit, E total 6
x 4 unit, I adalah 1 x 6 unit, dan seterusnya.
Not all
laminations follow
the "economy"
proportions,
though. Tidak
semua laminasi
mengikuti
"ekonomi"
proporsi,
meskipun. Here is
an example of a
lamination that
comes in one
piece, instead of
being divided into
an E and an I, and
that has the
windows
proportionally
much larger than
the EI lamination shown above. Berikut adalah contoh laminasi yang datang dalam satu
bagian, bukannya dibagi menjadi E dan saya, dan yang memiliki jendela secara
proporsional jauh lebih besar daripada laminasi EI yang ditunjukkan di atas. Such a
lamination is a bit more expensive to make, because the steel cut from the windows is
wasted, unless the manufacturer can find some other use for it. Seperti laminasi adalah
sedikit lebih mahal untuk membuatnya, karena baja dipotong dari jendela yang terbuang,
kecuali jika produsen dapat menemukan beberapa penggunaan lainnya untuk itu. But
being able to accomodate a much large winding assembly, it has some advantages in
certain cases. Tapi yang mampu menampung sebuah majelis berkelok-kelok banyak yang
besar, memiliki beberapa keunggulan dalam kasus-kasus tertentu.
These "non-economy" laminations were quite usual in Europe, many years ago, but
nowadays copper is so much more expensive than steel, that transformers are usually
designed to use more steel and less copper. Ini "non-ekonomi" laminasi cukup biasa di
Eropa, beberapa tahun yang lalu, namun kini tembaga jauh lebih mahal dari baja, yang
transformator biasanya dirancang untuk menggunakan baja dan tembaga lebih kurang.
And for that goal, the economy lamination is very well suited. Dan untuk tujuan itu,
laminasi ekonomi yang sangat cocok. So you won't very often come across a lamination
like this, unless you are restoring antique equipment. Jadi Anda tidak akan sangat sering
datang di sebuah laminasi seperti ini, kecuali Anda mengembalikan peralatan antik.
The laminations
should be thin,
and reasonably
well insulated
from each other,
to reduce eddy
currents to an
insignificant
value. The
laminasi harus
tipis, dan cukup
baik terisolasi satu
sama lain, untuk
mengurangi arus
eddy untuk nilai
tidak signifikan.
Typical
thicknesses vary
from 0.2 to 0.5mm, but higher frequency transformers (audio) use much thinner ones,
while extremely large transformers might use slightly thicker ones. Khas ketebalan
bervariasi dari 0,2 hingga 0.5mm, tapi transformator frekuensi yang lebih tinggi (audio)
menggunakan yang jauh lebih kurus, sedangkan transformator yang sangat besar
mungkin menggunakan yang sedikit lebih tebal.
The insulation is often applied at the factory that makes the big rolls of steel sheet, even
before stamping the E's and I's. isolasi sering diterapkan pada pabrik yang membuat
gulungan besar dari bahan pelat baja, bahkan sebelum stamping E dan I. Different kinds
of insulation are used: A thin oxide layer, a thin layer of enamel, or any of several
chemical processes. Berbagai jenis isolasi yang digunakan: Sebuah lapisan oksida tipis,
lapisan tipis enamel, atau salah satu dari beberapa proses kimia. Antique transformers
sometimes even used very thin paper! transformer Antique bahkan kadang-kadang
digunakan kertas yang sangat tipis!
When I was young, patient and overly eager to do things right, I painted each and every E
and I for my transformers, using diluted transformer varnish, to make a thin, nice layer.
Ketika saya masih muda, sabar dan terlalu bersemangat untuk melakukan hal yang benar,
saya setiap dicat E dan I untuk transformator saya, menggunakan pernis trafo diencerkan,
untuk membuat lapisan tipis bagus. The photo shows the steel for a 200 watt transformer,
drying. Foto menunjukkan baja untuk sebuah transformator 200 watt, pengeringan. Later,
getting old and lazy, I noticed that the layer of rust on old, recycled laminations is more
than enough insulation, and that the very thin and imperfect insulation that comes on new
laminations is enough too, even if it takes only a light scratch with the multimeter's test
probe to puncture it and get through to the steel. Kemudian, mulai tua dan malas, saya
melihat bahwa lapisan karat pada tua, laminasi daur ulang lebih dari cukup isolasi, dan
isolasi sangat tipis dan tidak sempurna yang datang pada laminasi baru cukup juga,
bahkan jika itu hanya membutuhkan goresan cahaya dengan uji probe multimeter untuk
tusukan itu dan sampai kepada baja. We don't need perfect insulation between the sheets!
Kita tidak perlu insulasi yang sempurna antara lembar! We only need enough resistance
to reduce eddy currents to a low level. Kita hanya perlu ketahanan yang cukup untuk
mengurangi arus eddy ke tingkat yang rendah.
Transformer steel is not all born alike. Transformer baja tidak semua dilahirkan sama.
Manufacturers will provide data sheets about their products (often on their web sites),
where you can see what they offer. Produsen akan memberikan lembaran data mengenai
produk mereka (sering pada situs web mereka), di mana Anda dapat melihat apa yang
mereka tawarkan. There are usually many grades, with vastly different loss
characteristics. Ada nilai biasanya banyak, dengan karakteristik kerugian yang jauh
berbeda. At a given flux density and frequency, a good material might have ten times less
loss than a cheap material! Pada kerapatan fluks diberikan dan frekuensi, material yang
bagus mungkin telah kehilangan sepuluh kali lebih kecil dari bahan murah! So it pays to
look, investigate, and decide intelligently what to buy. Jadi membayar untuk melihat,
menyelidiki, dan memutuskan apa yang cerdas untuk membeli. Thinner sheets normally
have lower loss, and the rest of the secret lies in the exact alloy. lembaran tipis biasanya
memiliki kerugian yang lebih rendah, dan sisanya dari rahasia terletak pada paduan yang
tepat. In any case, you need to know what material you have, to be able to make a
meaningful transformer design! Dalam hal apapun, Anda perlu tahu apa materi yang anda
miliki, untuk dapat membuat desain transformator bermakna!
Thick wires usually are coated with a sort of enamel that is very tough, an excellent
insulator, highly heat-resistant, highly resistant to solvents, and that clings to copper even
better than dirt does to children! kabel tebal biasanya dilapisi dengan semacam enamel
yang sangat tangguh, sebuah insulator yang sangat baik, sangat tahan panas, sangat tahan
terhadap pelarut, dan yang menempel tembaga bahkan lebih baik daripada kotoran tidak
untuk anak-anak! This enamel is usually yellowish clear, so that the wire coated in it
looks mostly copper-colored, but many exceptions exist. enamel ini biasanya berwarna
kekuningan jelas, sehingga kawat dilapisi di dalamnya tampak sebagian besar berwarna
tembaga, tapi banyak pengecualian ada. To solder the ends of these wires, it's necessary
to scrape off the enamel, using a sharp knife or similar tool. Untuk solder ujung kabel ini,
penting untuk mengikis dari enamel, menggunakan pisau tajam atau alat serupa. This
procedure would be too difficult with a thin, fragile wire, so that these thin wires are
instead covered with an enamel that has most of the same characteristics of the other one,
except the heat resistance: It will melt and turn into solder flux at a temperature a
common soldering iron easily achieves! Prosedur ini akan terlalu sulit dengan kawat, tipis
rapuh, sehingga kawat tipis ini malah ditutupi dengan enamel yang memiliki sebagian
besar karakteristik yang sama dari yang lain, kecuali tahan panas: Ini akan mencair dan
berubah menjadi flux solder di suhu besi solder umum mudah mencapai! This allows
easily soldering these wires, without previously stripping them. Hal ini memungkinkan
dengan mudah penyolderan kabel ini, tanpa sebelumnya stripping mereka. But
transformers using this latter kind of wire enamel cannot survive temperatures as high as
those using only the former kind of wire enamel. Namun transformer menggunakan
semacam ini terakhir email kawat tidak dapat bertahan hidup suhu setinggi yang hanya
menggunakan bekas jenis enamel kawat. The red wire on the right side in this photo has
this kind of enamel. Kabel merah di sisi kanan di foto ini memiliki semacam ini enamel.
But be careful with colors! Tapi hati-hati dengan warna! The clear wire on the extreme
left side also has solderable enamel, while the dark violet one in the middle is of the non-
melting variety! Kawat yang jelas di sisi kiri ekstrim juga memiliki email solderable,
sedangkan yang violet gelap di tengah adalah varietas non-mencair!
The thickness of the enamel layer depends on the wire thickness, the manufacturer, and
can sometimes be chosen: Some manufacturers will offer the wire with seeral different
thicknesses of enamel. Ketebalan lapisan enamel tergantung pada ketebalan kawat,
produsen, dan kadang-kadang bisa dipilih: Beberapa produsen akan menawarkan kawat
dengan ketebalan yang berbeda seeral enamel. In any case, the diameter specified by a
certain AWG number refers to the copper diameter, so that the complete wire, with
enamel, will be slightly thicker than what the AWG standard tells! Dalam hal apapun,
diameter yang ditentukan oleh sejumlah AWG tertentu mengacu pada diameter tembaga,
sehingga kabel lengkap, dengan enamel, akan sedikit lebih tebal daripada apa yang
standar AWG memberitahu!
Here is a wire
table for AWG
wire . Berikut
adalah tabel untuk
kawat kawat
AWG . It shows
the AWG number,
the diameter in
millimeters
excluding the
enamel, the
approximate
typical total
diameter including
the enamel (but
this varies
somewhat), the
cross sectional
copper area in square millimeters, the area of the square of window space occupied by
that wire in a transformer (including the enamel, of course), the current carrying capacity
at a typical, average value of current density, the resistance in ohms per meter, and finally
how many meters of that wire come in one kilogram, because enamelled wire is usually
bought by weight, not length. Ini menunjukkan jumlah AWG, diameter dalam milimeter
termasuk enamel, diameter perkiraan jumlah khas termasuk enamel (tapi hal ini
bervariasi agak), luas tembaga cross sectional dalam milimeter persegi, luas persegi
ruang jendela diduduki oleh kawat yang dalam sebuah transformator (termasuk enamel,
tentu saja), kapasitas arus pada nilai, rata-rata khas rapat arus, hambatan dalam ohm per
meter, dan meter akhirnya berapa banyak dari yang kawat datang dalam satu kilogram,
karena kawat diemail adalah biasanya dibeli oleh berat, tidak panjang.
This table has wires from AWG #1 to #40, and for the thickest ones I didn't calculate all
data. Tabel ini telah kabel dari AWG # 1 sampai # 40, dan untuk yang tebal saya tidak
menghitung semua data. But you should be aware that there are wires exceeding this
range! Tapi Anda harus menyadari bahwa ada kabel yang melebihi batas ini! The thinnest
I have ever used was #46. Paling tipis pernah saya gunakan adalah # 46. It breaks when
you blow at it! Rusak ketika Anda meniup itu! The photo here shows a #39 wire lying on
a #7 wire. foto di sini menunjukkan kawat # 39 berbaring di kawat # 7. The hairy thing
below is my floor carpet. Hal yang berbulu di bawah ini adalah karpet lantai saya. Note
that even this #39 wire is not much thicker than the hairs of this carpet! Perhatikan bahwa
bahkan ini # 39 kawat tidak lebih tebal dari pada rambut di karpet ini!
It's interesting to note that every three AWG numbers, the cross sectional area exactly
doubles. Sungguh menarik untuk dicatat bahwa setiap tiga AWG angka, luas penampang
persis dua kali lipat. Any deviation from this in my table is due to approximation errors.
Setiap penyimpangan dari ini dalam sebuah tabel saya adalah karena kesalahan
pendekatan.
Modern
transformers of
small to moderate
size are usually
wound on plastic
bobbins.
transformer
Modern ukuran
sedang kecil
biasanya luka di
kumparan plastik.
Here you can see
simple ones. Di
sini Anda dapat
melihat yang
sederhana. Some
bobbins have pins or terminals molded into them, others have one or two divisions.
Beberapa kumparan memiliki pin atau terminal dibentuk ke dalam mereka, yang lain
memiliki satu atau dua divisi. Some don't have the slits for terminals, which the ones
shown here do have. Beberapa tidak memiliki celah untuk terminal, mana yang
ditampilkan di sini miliki.
Typically for a given size of EI laminations, bobbins will be available in two or three
sizes, accomodating different numbers of steel sheets. Biasanya untuk ukuran tertentu
laminasi EI, kumparan akan tersedia dalam dua atau tiga ukuran, mengakomodasi
perbedaan jumlah lembaran baja. So you can vary the amount of steel in your transformer
not only by choosing the lamination size, but also the height of the lamination stack! Jadi,
Anda dapat bervariasi jumlah baja transformator Anda tidak hanya dengan memilih
ukuran laminasi, tetapi juga tinggi laminasi tumpukan!
Here is a little
transformer using
a divided (or split)
bobbin. Berikut
ini adalah sedikit
transformator
menggunakan
kumparan (atau
split) dibagi. This
is very practical,
because it
completely
separates the
primary from the
secondary
winding, making
it much easier to
achieve the degree
of insulation
required for safety. Hal ini sangat praktis, karena benar-benar memisahkan primer dari
gulungan sekunder, sehingga lebih mudah untuk mencapai tingkat insulasi yang
diperlukan untuk keselamatan. More about that later. Lebih lanjut tentang itu nanti.
The bobbin shown here was made from 1.5mm thick Pressspan, which is really too thick
for this small bobbin, but I had nothing better on hand. The kumparan yang ditampilkan
di sini dibuat dari 1.5mm Pressspan tebal, yang benar-benar terlalu tebal untuk ini
gelendong kecil, tapi aku punya apa-apa yang lebih baik di tangan. The pieces are cut to
size using a sharp knife (X-acto or the like), and glued together with cyanoacrylate
adhesive (instant bonder). Potongan dipotong untuk ukuran menggunakan pisau tajam
(X-acto atau sejenisnya), dan direkatkan dengan perekat cyanoacrylate (bonder instan).
The clever structural design of this super high tech bobbin holds it together perfectly
while the glue sets! Desain struktur pintar ini gelendong berteknologi super tinggi
memegang itu bersama-sama sempurna sedangkan lem set!
You must make the inner dimensions of the bobbin core a tad larger than the transformer
center leg, but JUST a tad, no more, unless you want to waste valuable winding space!
Anda harus membuat dimensi dalam dari inti gelendong tad lebih besar dari pusat kaki
trafo, tetapi HANYA anak laki-laki, tidak lebih, kecuali anda ingin membuang-buang
berharga berliku angkasa! The sides can be made pretty tight to the size of the
laminations, because if they don't fit at the end, they are easily enough cut or filed down,
even after the winding has been made. Sisi dapat dibuat cukup ketat untuk ukuran
laminasi, karena jika mereka tidak cocok di akhir, mereka cukup mudah dipotong atau
diajukan ke bawah, bahkan setelah penutupan telah dibuat. But the length of the bobbin
must be smaller than the window length of the core, by as much as 2 or 3%, plus any
tolerances of your manufacture! Tetapi panjang kumparan harus lebih kecil dari panjang
jendela inti, sebanyak 2 atau 3%, ditambah toleransi pembuatan Anda! Because it is
critically important that the E's and I's can touch each other properly, without being kept
separated by a bobbin that deformed during winding, and grew! Karena itu sangat penting
bahwa E dan aku
bisa menyentuh
satu sama lain
dengan benar,
tanpa terus
dipisahkan oleh
kumparan yang
cacat selama
berkelok-kelok,
dan tumbuh!
Be sure to at least
break the corners
as shown here, or
even better, round
them off. Pastikan
untuk istirahat
setidaknya sudut seperti yang ditunjukkan di sini, atau bahkan lebih baik, bulat mereka.
Otherwise the wire is guaranteed to tangle at the sharp corners during winding, and a wire
loop sticking out of the completed winding can ruin the whole thing! Jika kawat dijamin
untuk kusut di sudut-sudut tajam selama berkelok-kelok, dan loop kawat mencuat dari
selesai berliku dapat merusak semuanya!
Note that the junction of the bobbin's center piece is placed in the middle of one side, and
not in a corner. Perhatikan bahwa potongan persimpangan pusat kumparan adalah
ditempatkan di tengah-tengah satu sisi, dan tidak di sudut. It's next to impossible to
produce a reasonably symmetrical and precise bobbin when placing the junction in a
corner. Ini tidak mungkin untuk menghasilkan kumparan cukup simetris dan tepat ketika
menempatkan persimpangan di sudut.
If the material is thin compared to the bobbin size, the junction should be made by
overlapping the material. Jika material tipis dibandingkan dengan ukuran kumparan,
persimpangan harus dibuat dengan tumpang tindih materi. Of course, the overlapped
junction is always placed on one side that will end up outside the core window, so that
the added bulk has little detrimental effect. Tentu saja, persimpangan tumpang tindih
selalu ditempatkan pada satu sisi yang akan berakhir di luar jendela inti, sehingga
sebagian besar ditambahkan memiliki sedikit efek yang merugikan.
To bend this thick material in reasonably clean right angles, my technique is to use a
sharp knife to cut out a 90 degree wedge from the inside, along each bend line, leaving
only the outer third of the material intact. Menekuk bahan ini tebal di sudut kanan cukup
bersih, teknik saya adalah dengan menggunakan pisau tajam untuk memotong irisan 90
derajat dari dalam, sepanjang masing-masing garis tikungan, hanya menyisakan sepertiga
bagian luar dari bahan utuh. After that admittedly cruel treatment, the Pressspan eagerly
bends to my will. Setelah itu perlakuan kejam diakui, yang Pressspan penuh semangat
membungkuk untuk akan saya.
Most antique
transformers, and
many of the larger
modern ones,
don't use a real
complete bobbin.
transformer
Kebanyakan antik,
dan banyak dari
yang modern yang
lebih besar, tidak
menggunakan
kumparan lengkap
nyata. Instead,
they use only the
center former, and
no sides at all!
Sebaliknya,
mereka hanya
menggunakan
bekas pusat, dan
tidak ada sisi sama
sekali! It takes
some tricks and
practice to wind a
transformer like
this without
having the whole thing come apart many times over during winding, but for people who
have acquired enough practice, it's faster than making a real bobbin! Dibutuhkan
beberapa trik dan latihan untuk angin transformator seperti ini tanpa memiliki semuanya
datang kali selama bertahun terpisah selama berkelok-kelok, tetapi bagi orang-orang yang
telah memperoleh latihan yang cukup, lebih cepat dari membuat gelendong nyata!
Further down, I will show you a trick to make this kind of transformer, with high quality.
Lebih jauh ke bawah, saya akan menunjukkan trik untuk membuat semacam ini
transformator, dengan kualitas tinggi.
Note in this photo how the Argentinian maker of this transformer (back in 1931!) used
insulating material of several different thicknesses for the bobbin center, the interlayer
insulation, the interwinding insulation, and the terminal support. Catatan di foto ini
bagaimana pembuat Argentina ini transformator (kembali pada tahun 1931!)
Menggunakan bahan pengisolasi dari beberapa ketebalan yang berbeda untuk pusat
kumparan, isolasi interlayer, isolasi interwinding, dan dukungan terminal.
You might ask why any insulation material is required at all, if the wire is insulated by its
enamel layer! Anda mungkin bertanya mengapa setiap bahan isolasi diperlukan sama
sekali, jika kawat terisolasi oleh lapisan enamel nya! Well, the enamel is very thin, and
easily scratched. Nah, enamel sangat tipis, dan mudah tergores. It might survive as much
as a few thousand volts, but it might also break down with a lot less! Mungkin bertahan
sebanyak beberapa ribu volt, tapi itu juga bisa memecah dengan jauh lebih sedikit! It
depends on type, condition, thickness, temperature, and other factors. Hal ini tergantung
pada jenis, kondisi, tebal, suhu, dan faktor lainnya. So, wherever the voltage can exceed a
few tens of volts, some additional insulation needs to be used. Jadi, dimanapun tegangan
dapat melebihi beberapa puluhan volt, beberapa isolasi tambahan yang harus digunakan.
Specially between the primary and secondary, safety regulations ask for an insulation
good for at least 4000 volts, to avoid electrocuting somebody when there is a lightning
transient on the AC power network. Khususnya antara primer dan sekunder, peraturan
keselamatan yang meminta insulasi yang baik minimal 4000 volt, untuk menghindari
electrocuting seseorang ketika ada petir sementara pada jaringan listrik AC.
In antique transformers, the most usual insulating material was paper, impregnated with
something like beeswax, tar or the like. Dalam transformer antik, bahan isolasi yang
paling biasa adalah kertas, diresapi dengan sesuatu seperti lebah, tar atau sejenisnya. This
impregnation had several purposes: Mainly, it would seal the pores of the paper, making
it a really good insulator, while without the impregnation it would only insulate as well as
the same thickness of air! impregnasi ini memiliki beberapa tujuan: Terutama, itu akan
menutup pori-pori kertas, sehingga insulator yang sangat baik, sedangkan tanpa peresap
hanya akan melindungi serta ketebalan yang sama udara! But in addition, it kept moisture
out, it helped stick the thin wires in place during winding, and it improved the thermal
conductivity of the completed winding assembly. Tapi di samping itu, itu terus keluar air,
itu membantu tongkat kawat tipis di tempat selama berkelok-kelok, dan meningkatkan
konduktivitas termal dari berliku perakitan selesai.
It was also quite sticky, dirty, messy and gross. Ini juga cukup lengket, kotor, berantakan
dan kotor.
Modern insulating materials are far superior. bahan isolasi modern jauh lebih unggul.
Plastic sheets such as Mylar provide excellent dielectric strength and have no pores, so
they require no impregnation to realize their high degree of insulation. lembaran plastik
seperti Mylar memberikan kekuatan dielektrik yang sangat baik dan tidak memiliki pori-
pori, sehingga mereka membutuhkan pembuahan tidak untuk mewujudkan derajat
mereka yang tinggi isolasi. Nomex instead, with its fibrous structure, behaves like paper,
but both Nomex and Mylar are much better than paper at surviving high temperatures!
Nomex sebaliknya, dengan struktur berserat nya, berperilaku seperti kertas, namun kedua
Nomex dan Mylar jauh lebih baik daripada kertas bertahan hidup suhu tinggi! This is a
key characteristic of insulating materials: The temperature class. Ini merupakan
karakteristik kunci dari bahan isolasi: Kelas suhu. It's coded with a letter. Ini kode dengan
huruf. Paper would have an A or B rating, telling that it is fine for temperatures not much
above that of boiling water. Kertas akan memiliki rating A atau B, mengatakan bahwa itu
adalah baik untuk suhu tidak banyak di atas air mendidih. Different plastic insulation
materials instead are routinely available in classes as high as F, G or even H! Bahan yang
berbeda isolasi plastik bukannya secara rutin tersedia di kelas setinggi F, G atau bahkan
H! They can safely run much hotter than paper can. Mereka dengan aman dapat berjalan
lebih panas jauh dari kertas bisa.
Insulation materials come not only in many different variants, and temperature classes,
but of course also in many different thicknesses. bahan isolasi datang tidak hanya dalam
berbagai varian, dan kelas suhu, tapi tentu saja juga dalam ketebalan yang berbeda. You
choose the proper thickness so that it has enough dielectric strength and mechanical
strength, without taking up an undue portion of your valuable window space! Anda
memilih ketebalan yang tepat sehingga memiliki kekuatan dielektrik yang cukup dan
kekuatan mekanik, tanpa mengambil porsi yang tidak semestinya ruang jendela Anda
yang berharga!
Despite all modern materials, good old paper and cardboard is still used sometimes.
Meskipun semua bahan modern, kertas tua yang baik dan kardus masih digunakan
kadang-kadang. Mostly in its form known by the German word Pressspan, which means
"compressed chips", and is simply a very dense paper or cardboard. Sebagian besar dalam
bentuk yang dikenal dengan kata Jerman Pressspan, yang berarti "dikompresi chip", dan
hanya kertas sangat padat atau karton.
It's very good practice to soak a completed transformer in some impregnation varnish. Ini
praktek yang sangat baik untuk merendam transformator selesai dalam beberapa
impregnasi vernis. It will form fillets around wires, papers, and anything else. Ini akan
membentuk fillet sekitar kawat, kertas, dan hal lain. It will improve the insulation, make
the transformer highly moisture-proof, glue everything together so that nothing can rattle,
come loose, or chafe through, it will improve thermal transfer, and so on. Ini akan
meningkatkan isolasi, membuat transformator sangat kelembaban-bukti, lem semuanya
bersama sehingga tidak ada yang bisa berdetak, longgar, atau radang melalui, itu akan
meningkatkan transfer panas, dan sebagainya.
Varnish comes in several thermal classes, just like the insulation material, and also it
comes in variants that dry at high temperature, or at room temperature. Pernis datang di
kelas beberapa termal, seperti bahan isolasi, dan juga datang dalam varian yang kering
pada suhu tinggi, atau pada suhu kamar. My experience is that no varnish ever fully dries
at room temperature, and when you start using the transformer and it warms up, the
varnish inside will start drying, and stink! Pengalaman saya adalah bahwa tidak ada
pernis pernah sepenuhnya mengering pada suhu kamar, dan ketika Anda mulai
menggunakan trafo dan menghangat, bagian dalam vernis akan mulai pengeringan, dan
bau! So, it's necessary to apply heat anyway, regardless of what sort of varnish you use.
Jadi, penting untuk menerapkan panas pula, terlepas dari apa jenis pernis yang Anda
gunakan.
Now that you have turned into a person very knowledgeable about transformer materials,
let's turn to those pesky questions such as "how many turns do I have to wind?" Sekarang
bahwa Anda telah berubah menjadi orang yang sangat berpengetahuan tentang bahan
transformator, mari kita kembali kepada pertanyaan-pertanyaan sial seperti "berapa
banyak ternyata saya harus angin?" or "what wire size?" atau "apa kawat ukuran?" or
"how much power will I get?" atau "seberapa banyak daya yang akan saya dapatkan?"
1. 1. You need to repair/rewind a transformer that burned out. Anda perlu untuk
memperbaiki / mundur transformator yang terbakar habis.
2. 2. Your want to rewind an existing transformer, to produce the voltages and currents
you need, which are different from the original ones. Anda ingin mundur transformator
yang ada, untuk menghasilkan tegangan dan arus yang anda butuhkan, yang berbeda dari
yang asli. A variation of this case is when you want a certain voltage, at the highest
current that transformer can provide. Sebuah variasi dari kasus ini adalah ketika anda
ingin tegangan tertentu, pada saat ini yang tertinggi transformator dapat menyediakan.
3. 3. You have fixed specifications, want to design a transformer to optimally meet them,
and you will buy the core and all other materials. Anda memiliki spesifikasi tetap, ingin
merancang sebuah transformator secara optimal bertemu dengan mereka, dan Anda akan
membeli inti dan semua bahan lainnya.
Let's start with the
first case. Mari
kita mulai dengan
kasus pertama.
You MUST find
out why that
transformer failed!
Anda HARUS
mencari tahu
mengapa trafo
yang gagal! A
correctly
designed,
correctly built and
correctly used
transformer is, for
all practical ends,
eternal. Sebuah
benar dirancang,
dibangun dan transformator benar benar digunakan adalah, untuk semua tujuan praktis,
kekal. If it failed, there is a reason. Jika gagal, ada alasan. If you know that the
transformer was shorted, overloaded for a long while, exposed to intense lightning
transients, thrown into water, gnawed through by rats, exposed to corrosive substances, or
anything like that, then your best approach is to unwind it, count the turns, measure the
wire sizes, and rewind it exactly as it was originally made. Jika Anda tahu bahwa trafo itu
korsleting, kelebihan beban untuk waktu yang lama, terkena petir transien intens,
dilemparkan ke dalam air, menggerogoti melalui oleh tikus, terkena zat korosif, atau
apapun seperti itu, maka pendekatan Anda terbaik adalah untuk melepas lelah itu, jumlah
berubah, mengukur ukuran kawat, dan mundur persis seperti yang awalnya dibuat.
The photo shows an antique speaker field coil, mounted in my winding machine. Foto
menunjukkan kumparan pembicara bidang antik, dipasang di mesin saya berliku. I
unwind coils by pulling off the wire while having the thing spin in the machine, so that
the turns counter in the machine will do the pesky job of keeping count. Aku bersantai
kumparan dengan menariknya dari kawat sementara memiliki spin hal dalam mesin,
sehingga ternyata counter di mesin akan melakukan pekerjaan sial menjaga hitungan. The
problem, as illustrated here, is often that thin wires won't come off nicely! Masalahnya,
seperti yang digambarkan di sini, sering bahwa kawat tipis tidak akan lepas dengan baik!
They are stuck in place, and will break, then entire chunks of wire will come off all
together. Mereka terjebak di tempat, dan akan hancur, potongan maka seluruh kawat akan
datang dari semua bersama-sama. This often makes it hard to accurately count the turns.
Hal ini sering membuat sulit untuk secara akurat menghitung berubah.
In such cases you might simply estimate how many turns you didn't count. Dalam kasus
seperti itu Anda hanya bisa memperkirakan berapa banyak ternyata Anda tidak
menghitung. Or you can collect all the pieces of wire you removed, weigh them, calculate
the amount of wire from there, and calculate the turns number from it. Atau Anda dapat
mengumpulkan semua bagian kawat dihapus, menimbang mereka, menghitung jumlah
kawat dari sana, dan menghitung jumlah berubah dari itu. Or, instead of unwinding the
coil, cut it with a knife or better a Dremel tool, remove it in one block, measure the cross
sectional area of the entire winding, then remove a little piece of wire to measure the
diameter, and finally calculate the number of turns from this. Atau, bukan unwinding
koil, dipotong dengan pisau atau lebih baik alat Dremel, keluarkan dalam satu blok,
mengukur luas penampang dari seluruh berkelok-kelok, lalu hapus sepotong kecil kawat
untuk mengukur diameter, dan akhirnya menghitung jumlah putaran dari ini. Any of
these methods will usually be precise enough for non-demanding applications, and none
of it will be precise enough when you need anything critical. Setiap metode ini biasanya
akan cukup tepat untuk non-menuntut aplikasi, dan tidak ada akan cukup tepat bila Anda
butuh sesuatu kritis.
By the way, do you know how to precisely measure the diameter of a thin wire, when you
don't have a micrometer screw? Omong-omong, apakah Anda tahu cara tepat mengukur
diameter kawat tipis, bila Anda tidak memiliki sekrup mikrometer? Simple: You wind 10
or 20 or even more turns tightly on a former (such as a screwdriver stem), measure the
length of the coil with a common ruler, then divide by the number of turns to get the wire
diameter. Wikipedia: Anda angin 10 atau 20 atau bahkan lebih berubah erat pada
pengukuran (seperti batang obeng) bekas, panjang kumparan dengan penggaris umum,
kemudian bagi dengan jumlah putaran untuk mendapatkan diameter kawat. It's highly
accurate. Ini sangat akurat. Sometimes it's even better than using a micrometer screw,
which can flatten the wire if you apply too much torque! Kadang-kadang bahkan lebih
baik daripada menggunakan sekrup mikrometer, yang dapat meratakan kawat jika Anda
menerapkan torsi terlalu banyak!
But there are cases when you have a burned transformer, and no good reason why it
burned. It might have been a manufacturing defect, a huge transient, an overload that
went undetected, but maybe - the Gods of Electromagnetics forbid - that transformer
might have been misdesigned! In that case, painstakingly rewinding it with the same wire
gauges and turn numbers as original, will only produce a transformer that will fail again.
So, if you don't know why a transformer failed, re-do the design, and compare your
results with what the manufacturer did! Many manufacturers are cheapskates, and use
substandard transformers, in the hope that most clients will never use them intensively
enough to blow them up! This sends you straight to the section about the third case,
further down this page!
In the second case, when you want to rewind an existing transformer for new output
values, very often the transformer will already have a properly wound and healthy
primary winding. In such a case, keep it! There is no point in unwinding and rewinding
the primary, if it is fine. The calculation work for such a transformer is quite simple:
Before taking it apart, measure the voltage delivered by the secondary. Disassemble it,
unwind the secondary, counting the turns, and calculate the number of turns per volt from
this. Calculate the new number of turns you need for your desired voltage. Calculate
what's the largest wire size that will comfortably fit in the available space. Get the wire,
wind it, and assemble the transformer. The power rating will be the same as before, and
this allows you to calculate the current you can safely draw, at your new voltage.
And if you also want a new primary, well, do the same as above, but unwind and re-wind
all windings, according to the value of turns per volt you found out!
Do you know
what you can do
with all that wire
you remove from
old transformers?
Well, a super
trendy wig, like
the one shown
here, modelled by
my sister, is sure
to catch
everybody's
attention!
Otherwise, there
isn't really much
use for such wire.
It comes out
totally kinked,
stretched, broken,
scraped, with
varnish, wax or tar
sticking to it.
Don't even dream
about ever re-
using it in any
other transformer!
OK, now it's time to really start designing a transformer. Because this is what you have to
do in case 3, which is essentially creating a transformer from scratch. I hope you are still
fresh and aware of everything you learned in Transformers and coils , because you will
need it here to understand what's going on.
The design process starts with guessing the size of core you need, for the power you
want. If you are experienced in electronics, you will be able to make a reasonably close
first guess. Otherwise, use the data given by core manufacturers to get this first guess.
The core chosen will have a certain cross sectional area, and will have a certain window
area. Inti yang dipilih akan memiliki luas penampang tertentu cross, dan akan memiliki
luas jendela tertentu. The two multiplied are the "area product", which can be related to
the approximate power capability, with a reasonably simple, but nonlinear curve. Kedua
dikalikan adalah "area produk", yang dapat dikaitkan dengan kemampuan daya perkiraan,
dengan kurva cukup sederhana, namun nonlinier. This curve also depends on the quality
of the core material, and several other factors. Kurva ini juga tergantung pada kualitas
bahan inti, dan beberapa faktor lain.
The next step is calculating how many turns per volt you need on this core. Langkah
selanjutnya adalah menghitung berapa banyak putaran per volt Anda butuhkan pada inti
ini. To this end, you have to decide how much flux density you will put through your
core, and then you can apply the equations from Transformers and coils . Untuk tujuan
ini, Anda harus memutuskan berapa banyak fluks kepadatan Anda akan menempatkan
melalui inti Anda, dan kemudian Anda dapat menerapkan persamaan dari Transformers
dan koil . The optimal flux density might be anything from 0.8 to 1.6 Tesla, and
sometimes even outside this range! Kepadatan fluks optimal mungkin sesuatu 0,8-1,6
Tesla, dan kadang-kadang bahkan di luar kisaran ini! General rules of thumb are these:
Ketentuan umum praktis adalah:
- Larger transformers use lower flux densities. - Transformator lebih besar menggunakan
kepadatan fluks yang lebih rendah.
- Better core material uses higher flux densities. - Lebih baik menggunakan material inti
kepadatan fluks yang lebih tinggi.
- Transformers that are always energized, but rarely used at full power, use lower flux
densities. - Transformers yang selalu bersemangat, tapi jarang digunakan pada kekuatan
penuh, menggunakan fluks kepadatan rendah.
- Likewise, transformers that work at full power whenever energized, use very high flux
density. - Demikian juga, trafo yang bekerja dengan kekuatan penuh setiap kali energi,
gunakan kerapatan fluks yang sangat tinggi.
- Forced air cooled transformers use higher flux density. - Transformator berpendingin
udara paksa menggunakan kerapatan fluks yang lebih tinggi.
- Higher flux density produces better voltage regulation. - Kerapatan fluks Tinggi
menghasilkan regulasi yang lebih baik tegangan.
- Lower flux density produces less base loss. - Kerapatan fluks Lower menghasilkan
kehilangan dasar kurang.
- Lower flux density is less likely to produce humming noise, and magnetic stray fields. -
Kerapatan fluks yang lebih rendah adalah kurang mungkin untuk menghasilkan
bersenandung kebisingan, dan medan magnet nyasar.
- Lower flux density produces lower iron loss, but higher copper loss. - Kerapatan fluks
Lower menghasilkan kehilangan besi lebih rendah, tetapi kehilangan tembaga yang lebih
tinggi.
I have seen many text books giving design equations that result in a flux density of 1
Tesla in each and every transformer you calculate by them, like if that were a sacred rule!
Saya telah melihat banyak buku teks memberikan persamaan desain yang menghasilkan
kerapatan fluks 1 Tesla di masing-masing dan setiap transformator Anda menghitung
oleh mereka, seperti jika yang aturan suci! If you come across any such book, BURN IT!
Jika Anda menemukan buku-buku seperti, BURN IT! It's nonsense! Ini omong kosong!
While 1 Tesla indeed tends to produce a workable transformer in most cases, in at least
70% of all situations it's far enough from the optimal value to warrant some effort toward
optimization! Sementara 1 Tesla memang cenderung menghasilkan transformator bisa
diterapkan dalam banyak kasus, setidaknya 70% dari semua situasi itu cukup jauh dari
nilai optimal untuk menjamin beberapa upaya menuju optimasi! Specially in small
transformers, and in those using the better core materials. Khususnya di transformer
kecil, dan dalam yang menggunakan bahan inti yang lebih baik.
So, I suggest to start with a value chosen from the rules above, and then calculate the
transformer based on this value, analyzing the losses, heating, voltage drop, efficiency,
and so on. Jadi, saya sarankan untuk memulai dengan nilai yang dipilih dari peraturan di
atas, dan kemudian menghitung transformator berdasarkan nilai ini, menganalisis
kerugian, pemanasan, drop tegangan, efisiensi, dan sebagainya. Then change the flux
density, by 10 or 20%, and re-do all the calculations. Kemudian ubah kepadatan fluks,
dengan 10 atau 20%, dan kembali melakukan semua perhitungan. You will see what I
mean! Anda akan melihat apa yang saya maksud! There is a clear optimum value for flux
density in each particular case, and this value is very often sufficiently removed from 1
Tesla to make you wonder why some book authors still copy that "magic number" from
other, long gone authors! Ada nilai optimum yang jelas untuk kerapatan fluks dalam
setiap kasus tertentu, dan nilai ini sangat sering cukup dihapus dari 1 Tesla untuk
membuat Anda bertanya-tanya mengapa beberapa penulis buku masih salinan bahwa
"angka ajaib" dari yang lain, penulis pergi lama! Most likely they have no idea about the
matter they are copying. Kemungkinan besar mereka tidak tahu tentang masalah mereka
menyalin.
That said, sometimes I do wind my transformers for 1 Tesla, because there are cases
when this is really a good value! Yang mengatakan, kadang-kadang aku lakukan angin
transformator saya untuk 1 Tesla, karena ada kasus saat ini benar-benar nilai yang baik!
The loss calculation isn't very hard: The manufacturers of transformer steel specify the
loss of their products, as a certain amount of watts per unit of volume or weight, under
certain conditions of frequency and flux density. Perhitungan rugi yang tidak terlalu sulit:
Produsen baja transformator menentukan hilangnya produk mereka, sebagai jumlah
tertentu watt per unit volume atau berat, dalam kondisi tertentu frekuensi dan kepadatan
fluks. And the better of these data sheets also contain curves, or give equations, to
calculate the loss under different conditions. Dan lebih baik dari lembar data juga
mengandung kurva, atau memberikan persamaan, untuk menghitung kerugian di bawah
kondisi yang berbeda. That's about the iron loss. Itu tentang hilangnya besi. The total loss
of the transformer also includes the copper loss, which is caused simply by the current
flowing through the resistance of the wire. Jumlah kerugian sebesar transformator juga
mencakup kehilangan tembaga, yang disebabkan hanya oleh arus yang mengalir melalui
hambatan dari kawat. For a given flux density you get a certain number of turns per volt,
this allows you to calculate the total turns in each winding. Untuk kerapatan fluks
memberi Anda mendapatkan sejumlah putaran per volt, ini memungkinkan Anda untuk
menghitung total berubah di setiap berliku. Dividing the available window cross section
between these wires, insulation, bobbin, and inevitably wasted space, you get the wire
cross sections. Membagi bagian jendela tersedia silang antara kabel, isolasi, gelendong,
dan pasti terbuang ruang, Anda mendapatkan bagian kawat salib. From the dimensions of
the core, you can then calculate the total wire length, from this and the cross sections you
calculate the resistances of the windings, and from that and the currents you calculate the
power loss. Dari dimensi inti, maka Anda dapat menghitung panjang total kawat, dari ini
dan penampang anda menghitung resistensi dari gulungan, dan dari itu dan arus anda
menghitung daya yang hilang. It's easy! Sangat mudah!
In this sheet, you enter your data in the green area, and watch what happens in the orange
one. Pada sheet ini, Anda masukkan data Anda di daerah hijau, dan menonton apa yang
terjadi dalam satu jeruk. The first three values you have to enter are the ones that specify
the core. Tiga yang pertama nilai yang Anda harus memasukkan adalah orang-orang yang
menentukan inti. First is the center leg width of the lamination used, in millimeters.
Pertama adalah pusat kaki lebar laminasi digunakan, dalam milimeter. The 100mm width
given in the example is a pretty large lamination. Lebar 100mm yang diberikan dalam
contoh adalah laminasi cukup besar. You will typically use values between 12 and
50mm. Anda biasanya akan menggunakan nilai antara 12 dan 50mm. The sheet is based
on the proportions of the economy EI core, so that you don't need to enter any other
dimensions of the lamination. Lembar ini didasarkan pada proporsi inti ekonomi EI,
sehingga Anda tidak perlu memasukkan dimensi lain dari laminasi itu. If you happen to
be using a lamination that has different proportions than the economy EI, you should still
enter the width of the center leg, but later you will need to manually compensate for the
larger available window, by increasing wire size beyond that calculated by the sheet,
reducing the copper loss, and so on. Jika Anda kebetulan akan menggunakan laminasi
yang memiliki proporsi yang berbeda dari ekonomi EI, Anda masih harus memasukkan
lebar kaki pusat, tapi kemudian Anda akan perlu mengimbangi manual jendela yang
tersedia lebih besar, dengan ukuran kawat peningkatan luar yang dihitung oleh lembar,
mengurangi hilangnya tembaga, dan sebagainya.
The second value you have to enter about the core is the stack height, also expressed in
millimeters. Nilai kedua Anda harus memasukkan tentang inti adalah ketinggian
tumpukan, juga dinyatakan dalam milimeter. This is simply the height of the stack of E's,
well compressed. Ini hanyalah puncak tumpukan E, dikompresi dengan baik. This sheet
does not allow you to enter the stacking factor, which tells how much of the stack is
actually steel. Lembar ini tidak memungkinkan Anda untuk memasukkan faktor
penumpukan, yang menceritakan bagaimana banyak stack yang sebenarnya baja. There's
always some little space used by insulation, and even wasted space due to imperfect
compression. Selalu ada beberapa ruang kecil yang digunakan oleh isolasi, dan bahkan
terbuang ruang karena kompresi tidak sempurna. But the effect of this is small enough to
ignore, as long as you compress the stack well enough! Tetapi efek dari hal ini adalah
cukup kecil untuk mengabaikan, selama Anda menekan tumpukan cukup baik!
Good stack heights to use are from the same as the center leg width, to close to twice that.
Often you have the choice to use a certain lamination, stacked as high as the center leg is
wide, or use the next smaller lamination, stacked much higher, with both options
producing the same output. It pays to simulate both options, optimize each, and compare
the efficiency, voltage drop, weight, and cost! The differences can be profound.
And the third value is the loss factor of the steel material. This must be taken from the
datasheet provided by the manufacturer of the lamination. My sheet expects this loss
factor to be expressed in watts per kilogram of material, at a flux density of 1 tesla and a
frequency of 50 hertz. Many data sheets include the value in this exact form, but those
published by US companies might instead express the loss factor in an eclectic mixture of
metric, CGS and Imperial units! If that's what you have, you will need to convert the
value into its fully metric equivalent. You might want to modify the spreadsheet to do
that.
The value of 2 W/kg @ 1T and 50Hz is pretty representative for modern low cost
laminations. A modern ultra low loss material might be a lot better, while an antique or
ultra-cheap material might be significantly worse.
The next three values in that column are pretty obvious: You have to indicate the primary
and secondary voltages, and the frequency of operation. The secondary voltage refers to
the open circuit (no load) voltage. And the frequency will usually be either 50 or 60
Hertz. If you enter a frequency far away from this, it's quite possible that the loss
calculated for the material will be rather imprecise, so use this sheet with caution if you
need to design a transformer for a very different frequency.
In the right hand column, you have four values which are design decisions which you can
vary somewhat. The first is the all-important flux density. Just try varying that value, and
watch how things change in the orange output area! Specially, see what happens with the
iron loss. I have already given guidelines about what flux density to use. Use them and
see what happens in your case, when you change it.
The next is the amount of copper cross section you will allow for each ampere of current
in the windings. Reasonable values are about 0.25 mm^2/A for very small transformers,
increasing to 0.5 for large ones. 0.35 is typical for medium sized transformers (50 to 300
watts or so). When you adjust this value, the design of the transformer doesn't really
change, but the sheet will calculate a new set of currents, power, voltage drop, efficiency
and loss. With this parameter, you basically are telling the sheet how much you will
stress a particular transformer.
The fill factor expresses how much of the lamination's window will actually be filled
with copper. Faktor mengisi menyatakan berapa banyak jendela laminasi sebenarnya
akan diisi dengan tembaga. It can never be very high, because a lot of that area gets
inevitably filled out with the bobbin, the wire's lacquer, the air around the round wire, the
insulation between layers, between windings, and some space is always lost due to sloppy
winding, even if you are careful! Tidak pernah bisa sangat tinggi, karena banyak daerah
yang mendapat pasti diisi dengan kumparan tersebut, lak kawat itu, udara di sekitar kawat
bulat, isolasi antar lapisan, antara belitan, dan beberapa ruang selalu hilang karena
ceroboh lilitan , bahkan jika Anda berhati-hati! The value of 0.4 used in this example has
proven in practice to be achievable without much trouble. Nilai 0,4 yang digunakan
dalam contoh ini telah terbukti dalam praktek untuk dapat dicapai tanpa banyak kesulitan.
If you wind very carefully, and minimize the amount of space devoted to insulation, you
should be able to get up to 0.5. Jika Anda angin sangat hati-hati, dan meminimalkan
jumlah ruang yang ditujukan untuk isolasi, Anda harus bisa mendapatkan sampai dengan
0,5. But don't push this number too much, or you will end up with a transformer design
that you cannot actually wind! Tapi jangan mendorong jumlah ini terlalu banyak, atau
Anda akan berakhir dengan desain transformator bahwa Anda tidak bisa benar-benar
angin! On the contrary, if you have never before wound a transformer, and will do so by
hand, in a ragged, ugly winding, it might be a good idea to design the transformer with an
even lower fill factor, such as 0.3, to make sure you will be able to fit all the turns!
Sebaliknya, jika Anda belum pernah luka transformator, dan akan melakukannya dengan
tangan, dalam compang-camping, jelek berkelok-kelok, mungkin ide yang baik untuk
desain transformator dengan mengisi lebih rendah faktor, seperti 0,3, untuk membuat
yakin akan dapat cocok untuk semua berubah! Of course, using a lower fill factor means
simply using thinner wire, and this means that at a given amount of loss and heating, you
get less current. Tentu saja, menggunakan faktor mengisi lebih rendah berarti hanya
menggunakan kawat tipis, dan ini berarti bahwa pada sejumlah tertentu kerugian dan
pemanasan, Anda mendapatkan kurang lancar.
The fill factor can be pushed beyond 0.5 when you wind a transformer with square wire
(instead of round), or with copper tape separated by thin layers of insulation. Faktor
mengisi dapat didorong melampaui 0,5 ketika Anda angin transformator dengan kawat
persegi (bukan bulat), atau dengan tape tembaga dipisahkan oleh lapisan tipis isolasi. But
square wire is hard to find and a hassle to wind properly, and tape winding is acceptably
easy only for transformers that have rather few turns. Tapi kawat persegi sulit untuk
menemukan dan kerumitan untuk angin dengan benar, dan tape berliku bisa diterima
mudah hanya untuk transformator yang ternyata agak sedikit. This is often the case with
high frequency transformers used in switching power supplies, but not at line frequencies.
Hal ini sering terjadi dengan transformator frekuensi tinggi yang digunakan dalam catu
daya switching, tetapi tidak pada frekuensi baris.
The temperature rise defines how many Kelvins (same as degrees Celsius in this case)
hotter than the surrounding air and objects you want your transformer to run. Kenaikan
suhu kelvin menentukan berapa banyak (sama seperti derajat Celcius dalam kasus ini)
lebih panas dari udara sekitarnya dan benda-benda Anda ingin trafo untuk menjalankan.
You need to carefully choose this value, according to the highest ambient temperature
(inside the equipment!) at which your transformer will have to work, also taking into
account the highest temperature your wire, insulation material, varnish, glue, etc, can
survive. Anda perlu hati-hati memilih nilai ini, sesuai dengan suhu ruang tertinggi (di
dalam peralatan!) Di mana trafo Anda akan harus bekerja, juga mempertimbangkan suhu
tertinggi kawat, bahan isolasi Anda, pernis, lem, dll, bisa bertahan . And what's most
difficult, you will also need to estimate the thermal gradient from the innermost wire
turns (the hottest ones) to the transformer's surface! Dan apa yang paling sulit, Anda juga
akan perlu memperkirakan gradien termal dari kawat terdalam ternyata (yang paling) ke
permukaan transformator's! Calculating all this can be quite hard, and I can't give you
simplified equations for it. Menghitung semua ini bisa sangat keras, dan aku tidak bisa
memberikan disederhanakan persamaan untuk itu. Maybe you can find them elsewhere.
Mungkin Anda dapat menemukan mereka di tempat lain. The value of 70 Kelvins which
I used in the example design is relatively high. Nilai 70 kelvin yang saya gunakan dalam
contoh desain relatif tinggi. This is so because this transformer would work in open air,
not inside a housing, where the ambient temperature is never above 25 degrees Celsius;
also, I used class G or higher insulating material, wire and varnish throughout; and
finally, this transformer was carefully impregnated with varnish, giving it a reasonably
good thermal conductivity between winding layers. Hal ini karena trafo ini akan bekerja
di udara terbuka, tidak di dalam perumahan, di mana suhu sekitar tidak pernah di atas 25
derajat Celcius, juga, saya menggunakan G kelas atau lebih tinggi bahan isolasi, kawat
dan pernis seluruh, dan akhirnya, trafo ini hati-hati diresapi dengan pernis, memberikan
konduktivitas termal yang cukup baik antara lapisan berliku.
Finally, you can enter your local and current prices for enameled copper wire and
transformer steel laminations, to have the sheet calculate the cost of these main materials
for your transformer. Akhirnya, Anda dapat memasukkan harga Anda lokal dan saat ini
kawat tembaga enamel dan laminasi baja transformator, untuk memiliki lembaran
menghitung biaya bahan-bahan utama untuk transformator Anda. All the additional cost,
for the bobbin, insulation material, terminals, bolts and so on, is usually small compared
to the copper and steel cost. Semua biaya tambahan, untuk gelendong, bahan isolasi,
terminal, baut dan sebagainya, biasanya kecil dibandingkan dengan tembaga dan biaya
baja. The most expensive item is usually the wire, by far. Item yang paling mahal
biasanya kawat, sejauh ini.
The first two lines of the orange output area of my spreadsheet show some basic results
for that transformer: The cross sectional area of the magnetic core and of the winding
window, also the total copper area (after applying the fill factor), the turns per volt
constant that will be valid for all windings on this transformer, and the average length of
one turn, which is calculated as the average between the length of a wire that goes around
the center leg touching it, and one that goes around the entire winding package, touching
the outer legs. Dua baris pertama dari area output oranye dari spreadsheet saya
menunjukkan beberapa hasil dasar untuk trafo yang: Luas penampang inti magnet dan
dari jendela berkelok-kelok, juga daerah tembaga total (setelah menerapkan faktor
mengisi), berubah per volt konstan yang akan berlaku untuk semua belitan pada
transformator ini, dan panjang rata-rata satu giliran, yang dihitung sebagai rata-rata antara
panjang kawat yang berlangsung sekitar kaki pusat menyentuhnya, dan salah satu yang
terjadi di sekitar seluruh berliku paket, menyentuh kaki luar.
Then you have a line for the primary winding and one for the secondary. Kemudian Anda
memiliki saluran untuk gulungan primer dan satu untuk sekunder. Each of these lines
tells you the number of turns, the length of the wire need to wind it, the copper cross
sectional area of the wire, and the nominal current that will flow at full rating. The
number of turns isn't rounded off, so you will have to do that, because you can't wind a
fraction of a turn. You can fiddle with your voltage data to get the sheet to show round
numbers of turns. The wire length is based on the length of the average turn, so this will
be correct only if you wind the primary and secondary side-by-side, on a split bobbin. If
instead you wind the secondary on top of the primary, you will need less wire than
calculated for the primary, and more than calculated for the secondary. Anyway, these
lengths are not very useful in practice, because wire is bought by weight, not length. The
main situation where they are useful is when you have to wind a transformer with several
thin wires in parallel, because these are much easier to bend than one thick wire. In such
a situation, it's great to know how long the total winding is, so that you can cut the
strands and twist them together, before you start winding.
The remainder of the orange output area is divided into two columns. The left one shows
some important performance data of the transformer: There is the input power, expressed
in voltamperes, which is really more correct than watts. The value calculated by the sheet
does not include the magnetizing current; Calculating it would need additional
information about the core. But in medium to larger transformers, at least, the
magnetizing current tends to be small enough to be ignored.
Then comes the percentual power loss of the transformer, at full load. This includes both
the iron loss and copper loss. The output power is of course the input power minus this
loss.
Then we can see the voltage drop at full load. The value is calculated only from the
resistances of the windings. Any additional loss caused by imperfect coupling between
the windings is not considered here. So, if you use a poor core or winding technique, that
results in bad coupling, you should expect a somewhat higher voltage drop. Just for user
convenience, the sheet also calculates the output voltage under full load, which is based
on the voltage drop calculated above.
Below comes the weight of iron laminations and copper wire used in the transformer.
This has several purposes. One is knowing how heavy the beast will be, of course. The
other is knowing how much material you have to buy! If you use side-by-side winding of
the primary and secondary, you need to buy one half the calculated copper wire of each
size (plus some extra, of course, to be on the safe side). If instead you wind the secondary
over the primary, you need a little less than half of that weight of the primary wire, and a
little more than half that weight of the secondary.
And then, the sheet will calculate the total cost for laminations and wire, and also divide
this by the power, to give the cost per watt for your transformer, which is a good figure of
merit which you might want to optimize. Even while this calculation doesn't include the
cost for insulating material and other odds and ends, it's still a good reference.
The right side column of this area is about thermal matters. These tell whether your
transformer will survive, so don't take them lightly! The sheet calculates the power loss in
the iron, in the copper, and adds them to get the total power loss. Copper loss is
calculated at ambient temperature, though. When the wire heats up, its resistance
increases, and so its loss increases too! For this reason, take the calculated value with a
small grain of salt. The same is true for the voltage drop end efficiency calculations!
You need to be aware of the fact that the iron loss is essentially constant, regardless of the
load placed on the transformer, except for a little effect caused by voltage drop in the
windings reducing available magnetizing voltage, which causes a slight decrease in core
loss when the load gets higher ! The loss in the wire instead increases with the square of
the current taken from the transformer, and the value calculated by the sheet is for the full
rated current.
This gives you some big help in optimizing a transformer design. For example, a
transformer that will spend lots of time plugged in, but idling or loafing along at low
load, will see very little copper loss, but the iron loss will be there all the time. So, you
should design that transformer with a relatively low flux density, resulting in low core
loss, accepting a higher copper loss instead, by setting a smaller value of copper cross
section per ampere. After all, most of the time the rated design current won't be present,
so that the very high copper loss resulting in the calculation will be present only very
rarely, for short times! Transformers used in radio communication equipment, in audio
amplifiers, and many other uses, are best designed in this way.
The opposite case happens with transformers that are energized only briefly, but run at
full output power whenever energized. Examples of such use are microwave ovens and
spot welders. In such a transformer, iron loss always happens at the same time as copper
loss, and you can optimize the transformer to get the lowest total loss, regardless of how
it distributes between the iron and the copper. Even more, you might intentionally place
more loss into the core than the windings, based on the fact that the core is less prone to
be damaged by heat, has more thermal mass, and that the short operation time won't
allow the peak heat to distribute through the transformer! And then, such a transformer
that operates only for short times can be designed to have a really huge loss, because it
will have time to cool off between uses! These things are what makes microwave oven
transformers that deliver 800 watts be as small as a 200 watt transformer intended for
continuous service at low rate, and run at a flux density of 2 teslas or even more!
The heat produced by a transformer has to be dissipated to the surrounding air. The
spreadsheet calculates the approximate total surface area of the transformer, and finally
calculates a required thermal transfer coefficient, which expresses how much power the
transformer needs to dissipate per unit of surface it has, and per temperature rise allowed.
This coefficient tells you how difficult it will be to keep this transformer cool enough to
survive! The violet area below this coefficient includes referential values (not calculated
by the sheet) which you can use to try judging whether your transformer will be OK,
when you have it in a tight area, in a more open area, cooled by a fan, or immersed in oil.
I have my doubts about these values, specially aout the value for the oil-immersed
transformer, so please take these with a big grain of salt, and let me know if you have any
further, better, or more reliable data.
A typical design sequence using this spreadsheet would be to first enter the tentative core
size and loss, the required voltages and frequency, then start with something like 1 tesla
and 0.35mm^2/A, leaving the fill factor at 0.4 and setting the temperature rise according
to your transformer's materials and environment. Then you can observe the power and
current it would operate at, and the losses, efficiency, voltage drop, and also you would
get the thermal transfer coefficient which you can compare to the table to gain an idea of
whether the transformer will survive. You can then tweak the flux density and current
density, trying to get the characteristics into the range you need, without exceeding the
thermal possibilities. If you just can't find a combination that provides what you need,
you will have to try with a larger (or lower loss) core. Then you might want to explore
several different core sizes, optimizing each, and watch the cost, finally settling for the
design that best provides what you need, at the lowest possible cost, while staying in the
survivable thermal range.
This work with the spreadsheet is only the first step, though. When you have arrived at a
good design using the sheet, you need to tweak it to make it buildable with real, available
material! For example, you cannot get wire in any desired diameter. The sheet doesn't
know that; It might ask you for a wire measuring 1.2345 square millimeters, or anything
else. It's your job to see what wire you can actually buy, or maybe what wire you happen
to have in stock, and adapt the design. The AWG standard is quite finely stepped, so you
don't need to change the design very much to adapt it to standard AWG sizes. But I have
heard that in the US many stores only sell the even numbered AWG sizes of wire! That's
odd (pardon the pun), since even down here in less developed Chile I can easily buy all
AWG sizes, even and odd. If you are limited to even sizes only, you will have to make
bigger compromises.
A good approximation technique is to round the wire size to the nearest AWG size, or if
the values calculated fall just in the middle between AWG sizes, you might want to use
the next thicker wire for the primary, and the next smaller wire for the secondary. That
way the final losses and the amount of space required will be almost exactly the same as
calculated by the sheet.
If your transformer uses lots of turns of thin wire, you are about ready to start winding at
this point. But if it uses a winding that has few turns of a thick wire, you should check
how well (or how poorly) that wire fits in an integer number of layers, considering the
width of the bobbin, and about 5% of lost space due to the wire not being perfectly
straight. The problem is this: If the sheet calculates you need 48 turns of a certain wire
size, and it happens that you can fit only 15 turns per layer, then you will end up with
three complete layers, plus one additional layer in which you have just three turns! So the
total height taken up in the window by those 48 turns will be as much as 4 complete
layers, that could have 60 turns! Consequently, the winding might end up too high, and
won't fit the window! Then you cannot assemble the core, and you have to unwind that
winding, throw the wire away, get new (thinner) wire, do it again... you get the idea.
Anda mendapatkan ide. Try to avoid such frustration!
When you are in the situation just described, it would be wise to try the next smaller wire
size. It's very likely that this smaller wire size would accomodate 16 turns per layer, thus
allowing you to wind the 48 turns in three nice, clean, complete layers, and using up a
little bit less space than calculated by the sheet. This can in turn allow you to use the next
larger wire size for the other winding, which will almost completely compensate for the
higher loss and voltage drop of the smaller wire you used for the 48 turns!
Putting it in short words, you have to pick the best wire sizes for your transformer so that
their cross sections are close enough to the calculated values, but still allow a good,
space-saving distribution on the bobbin and thus inside the window area of the core.
Sometimes you might end up with a high current transformer requiring a very thick wire.
Such a wire is very stiff! If the bobbin is small, you might not be able to bend that thick
wire tightly enough around the corners of the bobbin. The result would be a huge loss of
space, and the completed winding wouldn't fit in the window, making it unusable. To
work around this problem, you can replace one thick wire by a bundle of seven wires,
each of which is one third as thick as the single wire. Such a seven wire bundle twists
very nicely into a round cable, and is more then 20 times as flexible as the single thick
wire! It costs only very slightly more money, and performs great. So, this is the way to go
when you have a need for such thick high current conductors. It's good to know that an
AWG number 10 units higher is roughly one third the diameter. So, if you would need a
#7 wire and this is too thick to wind comfortably, you can use 7 strands of #17, lightly
twisted together.
Sometimes instead of using one thick wire you will also find it convenient to wind with
two or three thinner wires in parallel, without twisting them. This technique can
significantly ease the distribution of a winding in entire layers.
Another hint: Most transformers use some thin and some thick wire. For transformers that
have the windings on top of each other (instead of side-by-side), I suggest to always first
wind the windings that use the thin wire, then the ones using thicker wires, regardless of
which will be primary and secondary. This allows to wind the stiffer wire on the outside,
where the bending radius required is a lot larger and thus less demanding. Whether the
primary is under or over the secondary has no significant effect on performance.
You might have noticed that my spreadsheet only considers transformers that have a
single primary and a single secondary. But many transformers use several secondaries,
and some use two or more primaries! In such cases you will have to do some more work
manually. You should use the sheet to calculate the transformer, simulating only the main
secondary, tweaking it for the total power, and then manually reduce the wire size of that
secondary proportionally to the percentage of the total transformer power this secondary
will have to deliver. Then you can add the other windings, calculating their turns number
from the turns per volt calculated by the sheet, and the wire size from the current they
have to carry, and the mm^2/A you selected.
Or if you have two equal secondaries (or two equal primaries!), you can let the sheet
calculate a single secondary (or primary) of twice the voltage. That will produce the
correct number of total turns and wire sizes. You only have to remember to cut the wire
after having wound half of the turns, bring it out, start again and wind the second half!
You might have noticed that I didn't assign additional wire cross section to the primary,
to account for the magnetizing current. The reason is that the magnetizing current is
normally much smaller than the main current, and on top of that, the magnetizing current
is 90 degrees out of phase with the main current! The vectorial sum of the main and
magnetizing currents is so little higher than the main current alone, that there is usually
no need to consider the difference.
You might also miss any discussion of core saturation. The problem is that's quite hard to
discuss saturation of silicon steel cores, because they just don't saturate at a well defined
level of flux density! Instead, the saturation is quite gradual: It might start at a level as
low as 0.5 tesla, become more noticeable at 1 tesla, then the curve bends further, but even
at 2 tesla there might be a significant amount of permeability left! The effect of this is
that with increasing flux density, the magnetizing current increases more sharply, but it
would be really hard to reach a level where the saturation makes the transformer stop
working. So, the most important consideration about flux density is the sharply increasing
core loss. Only when you are using very high flux density, would it be a good idea to
allow some additional cross section for the primary wire, to accomodate the larger
magnetizing current.
Very often,
winding a
transformer for a
hobbyist will start
with unwinding an
old, burned one!
The photo shows
part of the guts of
a Heathkit tube
tester from the
1950's, which was
given to me in
damaged but
restorable
condition by my
friend Renato
Menare. Its power
transformer
worked, but got
extremely hot in just one minute of operation, and started smelling burned after two
minutes.
After restoring the tube tester, without touching the transformer, I used it for about a year,
switching it on only for a minute at a time to test one tube, and then letting it cool off. But
eventually the inevitable happened: The transformer burned out, filling my home with
smoke.
Such a tube tester transformer is one of the worst nightmares any transformer maker can
get: It has two secondaries, each of which has a huge number of taps to provide all the
different filament and plate voltages needed by any of the thousands of different tubes
around in the 1950s! It takes patience to rewind such a thing. Every few turns you have to
install a tap!
The first step is removing the transformer from the circuit, unsoldering all wires and
taking notes which wire goes where. The fact that may wires are the same color doesn't
help. Then, the core has to be disassembled. To do that, you first remove the bolts, then
push a sharp knife between the first and second lamination, prying them apart to break
any glue or varnish or rust between them, then grab the lamination with flat pliers and
wiggle it out. Depending on how much the core was compressed during manufacture, this
can be quite hard to do, and one or two laminations might be damaged in the process.
That's not the end of the world, the transformer should later work even with one or two
laminations less. Usually, after removing the first few, the others come out easily.
Sometimes each lamination needs a little help with the knife to come loose, while in other
transformers the core falls apart on its own as soon as compression is relieved.
You should also save the wire, so you can measure its diameter and find out what sizes of
wire you need to buy.
As the layers of wire and paper come off, things usually turn darker and ever darker! This
is because transformers work hottest at the inside. This picture shows severely carbonized
insulation, both the paper and on the connection wires. Probably the paper slowly
carbonized, becoming slightly conductive, causing further loss, further heating, until the
beast failed for good. This is the problem of paper insulation!
Don't do such a job in your parent's bedroom, because as you can see, it's messy! Even
the kitchen might not be the best place to do it. Neither mothers nor wifes tend to like this
sort of transformer autopsy!
When not even the bobbin is usable, you will need to make a new one, or find one that
fits. I was lucky this time, and found one in my junk box (aka treasure chest) that just fit
this core, and even had side walls! It's a great thing that core sizes are standarized, even if
several different standards exist...
It's
probably high time to introduce my transformer winding machine. Here you can see it in
all its glory, somewhat obscured by the messy background (my workbench). Amateur
radio friend Enrique Villanueva, CE5FSB, gave me this machine when I was still a
schoolboy. That was many years ago, Enrique is no longer in this world, but I remember
him every time I wind a transformer! He was a true gentleman, and always helpful.
This machine is simply a motor and switchable two-speed gearbox with central neutral
position, that drives a three-pronged thorn, opposed to which is an adjustable centering
screw. It's quite handmade, but does the job well. The fast speed is about 120 rpm, and
the slow one is about 15 rpm.
I added a turns counter to it. Saya menambahkan ternyata counter untuk itu. It didn't have
one when I got it. This turns counter came from a surplus store, out of a broken gas
meter. It advances 4 counts per revolution, so I coupled it to the machine's drive shaft via
a 4:1 speed reduction, getting exactly one count per turn. To make this coupling, I made
two gears! One was cut from the lid of a coffee can, has 16 teeth, and is visible in the
picture. The other one was made from a piece of wire, has 4 wire loops acting as teeth,
and is hidden in the photo. It's crude, but was cheap and has worked well for about 30
years now! I can hardly even try to calculate how many transformers I have wound wit
this machine!
When winding a
transformer, you need to
have the wire unwind
straight and cleanly from
the spool on which it's
sold. If you simply stand
the spool on the ground,
the wire will twist while
unwinding, curl up, and
kink. At that point, you
can throw it away and
start anew! So, don't.
Instead, you need to
fashion some device that
allows the spool to rotate,
letting the wire unwind
without kinking. This
photo shows one of the
methods I often use: A
screwdriver, serving as axle, held in a vise.
Sometimes I'm too lazy to set up the vise. In those cases I simply hold that same
screwdriver between my knees while winding the transformer!
Modern small split bobbin transformers are normally wound in a very untidy way: The
operator at the factory simply lets the machine run, and fill the bobbin section with wire,
letting it build up wherever it wants to. There are no layers, no insulation between layers,
it looks poor, is less reliable, the fill factor is less good but still acceptable, and it's fast
and cheap to do.
The winding shown in this photo, instead, is a hybrid of both techniques. The winding is
split up into just a few layers, two or three or so, but each layer is wound thick, with the
wire turns actually building up on each other. I let the machine run and guide the wire to
let it slowly fill the layer from one side to the other (never going forth and back several
times!), letting the windings build up to the desired height, about two millimeters or six
wire diameters in this case. When that ugly layer is complete, I apply a coating of self
adhesive tape as insulation, and then wind the next layer. It's almost as quick to do as a
totally wild winding, but significantly more reliable.
A word about tapes: Transformer parts stores sell self-adhesive mylar tape, usually
yellow, in several thicknesses and widths. This is a good material, and you should use it.
But I often don't have it on hand, and use alternative materials. Vinyl insulating tape can
be pressed into service, but isn't great , because it gets very soft when hot, and the wires
can press through it. Much better, even if you don't believe that, is painter's masking tape!
It has just about the optimal elasticity, is thin, cheap, comes in several widths, holds up
well when hot, and looks pretty good on transformers for antique equipment, on which
any plastic tape would look out of place! Masking tape is what I used for this
transformer.
A question many
newcomers have
is how to handle
the ends and taps
of windings.
When the wire is
rather thick and
robust, you can
simply let the end
stick out of the
bobbin! In that
case it's good practice to protect that wire by a piece of spaghetti (I don't mean an Italian
noodle, but a piece of plastic or fiber hose that looks much like it). It should ideally be
only slightly thicker than the wire. You slip it over the wire, and anchor it in the winding
assembly, with adhesive tape and the pressure of the windings. It will protect the wire
from chafing, and provide additional insulation at places where the wire might pass very
close to other wires or to the core.
But thin wires should not be treated like that. They are too fragile, and might very easily
break later, forcing you to rip up and rewind the whole transformer! Instead, you should
take some pigtails of stranded, plastic-insulated wire, strip and tin the ends, solder the
thin enamelled wire to the end of a pigtail, and embed it in the winding like is shown in
this photo. You need to place enough layers of insulating material both under and over
the connection, to make sure that no sharp tip or edge of the wires may puncture through
the insulation. This adds quite a lot of bulk, so of course these connections must be done
on the sides of the bobbin that will end up outside the core's window!
When you solder these connection, make absolutely sure that the enameled wire stripped
properly in the solder bath. It's very frustrating to end up with a nice new transformer,
that has one winding that doesn't conduct, because of a badly done connection! In this
photo, the first one and a half loops of the thin enamelled wire around the pigtail didn't
strip, but the other three loops did, so the connection is secure.
One word about safety: Between the primary and secondary windings, and at any place
where there might be high voltage, you need really good insulation. After connecting this
pigtail, which is the end of the primary winding, I had to apply such safe insulation.
When doing it with adhesive tape on a bobbin like this, it's done by winding several
layers of that tape, and winding it not only all the way to the side walls, but even a bit up
on these walls, forming a kind of cradle bedding for the secondary winding. You need to
get either a perfect seal between the tape and the side walls, or having so much tape, and
the wire moved far enough toward the middle of the bobbin, that the creepage distance
from primary to secondary, around the insulation, is at least 4 millimeters. This is even a
legal safety requirement!
After
winding
the two
secondaries with their lots of taps, and re-assembling the core, the finished transformer
looked like this, in all the glory of its dozens of connecting wires! In this Heathkit tube
tester, the wires connect directly to the circuit. In other cases, these wires would be neatly
dressed and soldered to terminal strips, which are either embedded in the outer layers of
insulation in the winding assembly, or bolted to the core.
I built the simple but effective setup shown in the photo. A big wooden bobbin was made,
with dimensions such that the complete winding package for the transformer would
precisely fit inside. Note that this bobbin is just the support for winding! It will be
removed before final assembly of the transformer. For this purpose, it's held together by
screws, and the wooden pieces on the inside are designed so that they can be easily
removed from the finished coil assembly. This big wooden bobbin got fitted with a hand
crank, and mounted on a steel tube serving as axle, which was clamped to the workbench.
Each wooden piece of the bobbin was separately wrapped in kitchen wrap (saran wrap,
Sichtfolie) before assembling the bobbin. This assures it can be disassembled after
varnishing the winding assembly, without the wood sticking to the coil assembly!
The spools of wire for these big transformers weigh 30 kg for the secondary, and 25kg
for the primary. So I made a simple but sturdy support structure for them and placed it at
the work site.
Since the
Pressspan might
carbonize and
become slightly
conductive at high
temperature, I
wound two layers
of high
temperature NMN
laminate over this
core, to insure
permanent safe
insulation between
the winding and
the core. It's
temporarlily held
in place with plain
office type adhesive tape, but this tape is later removed when winding the wire, to keep it
from carbonizing and possibly causing trouble.
This transformer has sufficiently few turns and thick wire to wind it in orderly layers,
separated by insulating sheets. To keep the whole thing from falling apart, I bound the
layers together with cotton straps, and to make sure the wire turns don't get closer to the
edge of the bobbin than 5mm or so, I wound cotton ropes at the edges, used as spacers.
These ropes will be removed later.
The photo shows the assembly, ready to start winding. A double rope makes one turn on
each side of the bobbin, enough spare rope for the successive turns is coiled up on screws
driven into the bobbin, and the cotton straps are installed and coiled up too. The wire end,
protected by a piece of high temperature red fiber spaghetti, is anchored in a hole drilled
into the wooden bobbin. Time to start winding!
Since the wire isn't ever perfectly straight, it's impossible to completely eliminate air
between the turns. That's why you have to consider a safety factor when calculating how
many turns you can fit in each layer!
The next layers instead are easier to wind, because the wire will embed itself slightly in
the depressions between two turns of the previous layer, automatically assuming the
correct spacing. Note that this produces either winding layers which alternatingly have
one more or one less turn, or else the windings with the same number of turns in each are
alternately offset sideward by one half wire diameter, respective to each other. You need
to consider this when designing the transformer, when you intend to do a neat, tight
winding like this.
This photo was shot during the winding of an intermediate layer of the primary.
The wire and the cotton ropes are placed between the ends of the insulation sheet, for the
transition from one layer to the next. Said in a different way, the insulation sheets are
simply wound into the coil of wire and rope.
After this, the insulation layer can be wound, and then the ropes and the wire for the next
layer.
Then several layers of insulating material are wound, since the voltage between primary
and secondary can reach 10kV or more during a nearby lightning strike! These
transformers were built to send power over a 600 meter long outdoor transmission line, in
a mountainous and lightning-prone area.
Since the secondary winding uses much thicker wire, the spacing rope needs to be thicker
too. I used one strand of thick rope for the secondary, and two strands of thinner rope for
the primary. As a result, both windings are spaced about the same 5mm from the sides.
The secondary is
wound just like
the primary. In
this case it was a
little more
complicate,
because I actually
wound two
secondaries, each
of them having a
wire half the cross
section calculated
in the sheet. On
top of that, each of
the secondaries is
center-tapped
too.This allows
me to do several
clever things with
my transformers, and as a bonus lets me wind with a thinner, more manageable wire. This
is #7, still stiff enough!
The photo shows the completed secondary, before applying the final layers of insulation.
You can see the spacing ropes,
and how the cotton strap will hold
the last turn.
At this point, the winding assembly is ready to remove part of the wooden bobbin, and
start the varnish impregnation process.
After removing all those ropes, the winding assembly looks like this. Note how the wires
are nicely tucked in between the insulation layers.
While the cotton straps do a great job holding the end turns of each layer in place,
preventing them from falling out and the whole thing springing open, this assembly is
still far too weak to be used like this. Considerable forces act on wires of big
transformers. They need to be secured very well.
And a further
closeup showing
how the straps
hold the wires,
and bend the
insulation, always
maintaining a safe
creepage distance.
Without removing the other remaining parts of the wooden bobbin, I soaked the entire
winding assembly in impregnation varnish. I poured the varnish in from the top, until it
flowed out profusely from the bottom. Then I let the assembly soak, let the excess drip
off, and let it dry somewhat on the surface.
But this is an oven-drying varnish, so it needs to be heated, or it will never dry. I do have
a thermostatically controlled oven - but not large enough to fit a winding assembly of this
size! So I applied enough DC current to the primary winding to slowly heat up the whole
thing to a temperature high enough to dry the varnish.
Every transformer
varnish has a
recommended
drying
temperature. To
get it right, I
occassionally
removed the
power supply, and
measured the
resistance of the
primary winding.
Comparing to its
resistance when
cold, and
considering the
thermal
coefficient of the
resistance of
copper, it's easy to calculate the internal temperature! Then I adjusted the DC current to
keep the temperature just right.
I removed the other wooden bobbin side, and the spacing ropes on that side, when the
exposed side of the assembly seemed to be dry. The newly exposed side was still fresh,
so drying continued with the assembly supported only by the wooden parts in the center.
When the varnish stopped smelling, signalling that it was dry, I removed all of the
remaining wooden parts. This was quite easy, thanks to the kitchen wrap, which stayed
partially adhered to the Pressspan core. In this photo you can see that. The brownish color
is that of the varnish, while the near black sections inside the assembly are partially
carbonized kitchen wrap. This stuff doesn't endure the temperature the varnish needs to
dry! But no harm was done, except to the wrap, which is of course irrelevant.
At this point, the winding assembly has a monolithic feel, with everything firmly glued
together by the varnish. It could actually be used without further work, but the edges of
the thin insulation material are quite fragile. Any object striking them could bend or even
break them, compromising the creepage distance and thus the safety of the transformer!
2000 volts at 10 kilowatts is not something to take chances with.
So I filled these areas with
silicone caulk. This
material is available,
inexpensive, easy to work
with, tixotropic,
permanent, an excellent
insulator, and endures
very high temperature. In
short, it's a nearly ideal
material for this task!
There is only one point to
watch: Be sure to use the
neutral curing type, not
the more common, acid
curing one! The last thing
you want to do is
releasing highly corrosive
acetic acid into your new transformer!
The color of the silicone is your (or in this case, my!) choice.
I didn't do a particularly neat caulking job, but the point was to get the edges sealed and
protected, not to do a work of art.
After all E's have been inserted, the I's are slid into the voids. After that, two wooden
blocks and a big hammer are used to knock all the laminations into their correct positions,
aligning them with each other, and specially, align the screw holes of all the laminations!
In small transformers this is done with clamps. But big ones, like this, use bolts. Often
you won't find real bolts long enough and thin enough, though! In those cases, buy some
threaded stock, which is sold in great lengths, cut it to size (a Dremel tool with a heavy
duty cutoff disk does this very nicely!), and use it with washers and nuts on each end.
Installing the bolts just on the core leaves you with an unevenly compressed lamination
stack, and what's more important, with nothing to mount the transformer! For that reason
usually some angle stock is used . It distributes the force over much of the core, and
provides convenient surfaces to drill mounting holes into.
Some transformers use formed caps instead, or complete steel frames.
Note the insulation sheets under the washers of the bolts! Depending on the specific
transformer, they might make any difference, from barely noticeable to dramatic!
At this point, the transformer is truly ready for trying. If it still hums, you can try
tightening the bolts even further, and inserting wooden or plastic wedge pairs between the
winding assembly and the core center leg, to compress the latter. If even this fails, which
is often the case, then you have no better option than once again getting your varnish can,
and soak the core in varnish! You can loosen the bolts, let varnish flow into every space,
then tighten the bolts again and warm up the whole transformer by applying a suitable
amount of DC for at least a full day. I have yet to see a transformer that still hummed
after that treatment!
Depending on the
application,
different things
can be done with
the connections. If
they are made of
flexible wire, they
might be directly
wired into the
circuit. In small
transformers,
often plastic
bobbins with pins
are used, and the
windings are connected to these pins, like shown here, and then the whole transformer is
soldered to a printed circuit board. The example shown here is a current sensing
transformer, which also has a one-turn, high current winding, which is brought out
separately from the bobbin pins.
Often terminal
strips are attached
to the winding
assembly, and the
windings are
connected there.
But in larger
transformers, the
most common
practice is bolting
terminal blocks to
the transformer,
and connecting the
wires there. I did this with my large transformers, leading to the final product shown in
the very first photo of this web page. That system is more solid and reliable then most
others, and allows repeated solderless disconnection and reconnection, which I need a
few times per year to reconfigure my transformers for different conditions of usage.
Some people wonder whether they should try winding their own transformers, or if they
should instead shell out big $$$ to have the job done by a professional winding shop. I
can only tell you one thing: If you had the patience to read this long web page from start
to end, then you most certainly also have the patience required for winding your own
transformers!!!