The right toroidal transformer for your application. This article examines some of the factors that can help in choosing the right transformer for your application.
Magnetic Core Material: As you may have realized, the magnetic core is an integral part of the transformer, so the material used must be of high quality. Below are some popular materials for building cores.
The cores are made of ferrite materials such as cobalt, zinc, manganese, and nickel. Ferrite cores made of nickel zinc ferrite and manganese zinc ferrite materials are other alternatives. These core materials have low saturation flux density, permeability, and Curie temperature.
High-quality virgin steel is also used to manufacture the core. A continuous strip of high-quality virgin steel tightly woven, without air gaps, makes the core. This helps avoid vibrations. Both materials allow engineers to design transformers with specific magnetic induction points. This helps increase their efficiency while reducing losses.
Powdered metal cores such as carbonyl iron and molypermalloy are used to make the cores.
Wire: The wire is called a winding. Most toroidal transformer designs have two windings - a primary and a secondary. Some designs may also have two secondary windings. These windings are made of copper and aluminum. Of these, copper is the most popular choice, but aluminum was chosen because of its price advantage. Copper has the excellent current-carrying capacity as well as thermal and electrical properties.
Insulation Material: The safety and performance of a toroidal transformer depend on the insulation material used. Strong insulating materials can build strong impact resistance, reducing the possibility of leakage and short circuit. Paper, varnish, polyester, and mineral oil are some common insulation materials used to protect windings. Most windings use cellulose insulation with mineral oil.
Winding Technology: The windings of a transformer play a key role in its function. If not properly wound, the wire may leak electricity. Special consideration must be given to winding techniques. The bank winding technique is the most popular technique. In this technique, wire is wound around a toroid to form a pie-shaped portion. An equal number of odd and even segments are formed around the loop coil in clockwise and counterclockwise directions. Repeat this winding until the toroid is completely covered. This type of winding helps to reduce the maximum turn-on voltage stress on the conductor insulation.
Magnetic Shielding: Toroidal transformers have low magnetic flux leakage compared to other types of transformers. Some applications may require additional earth leakage protection, in which case an additional thin silicon steel sheet can be used. A shield is formed around the circumference of the toroidal transformer and secured using an overwrap.
Encapsulation Material: The transformer is encapsulated to protect it from vibration and shock. Thermoplastic materials are often used to encapsulate the core. Many different types of epoxies can be used to encapsulate the entire toroidal transformer.
Dipping: Some transformers may be designed with small wire sizes and low power ratings. These transformers may be impregnated to increase their efficiency to avoid any short circuits or noise. For example, when these transformers are used in audio applications, the toroidal cores are impregnated to prevent hum.
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