Experimenting With High Frequency Transformers

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Shyam Guru Join Date: Aug 2006 Location: AM-51, Deen Dayal Nagar, Gwalior, Madhya Pradesh, MP 474001, India Posts: 3418 Good Answers: 32	Experimenting With High Frequency Transformers 05/27/2011 4:14 AM
	Hello Friends Finally I have come to these parameters for 25kHz to 100kHz transformers for about 1kW power. ETD54, ETD59 Ferrite core, Bobbin and High Temperature Wire.High Temperature wire as coils are getting heated for 1kW switching action. I have decided that we make these transformers and see their performance rather than procuring ready to use and running into problems. I am using MOSFETs for switching and will soon change to IGBTs. I am also having pulse width control and lots of noise filters in plan to get somewhat cleaner sine wave at the output. Small engineering team is working on this and project is funded by another company Insight Engineering Systems Private Limited, Mumbai for US$11111.11 a good figure I suppose. Idea is to develop 25kHz sine wave inverter initially and see what else can be done at higher frequencies also up to 100kHz. Our team has only about 60 days to finish this first developmental work. I will post my experience here so all those are keen in this area may join this discussion. __________________ Prof. (Dr.) Shyam, Managing Director for Sensors Technology Private Limited. Gwalior, MP474001, India.
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TonyS Guru Join Date: Aug 2010 Location: Resting under the Major Oak Posts: 4347 Good Answers: 181	#1 Re: Experimenting With High Frequency Transformers 05/27/2011 9:59 AM
	Stack em high, sell em cheap! Shouldn't this be in commercial? __________________ The reports of my death are greatly exaggerated.
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Shyam Guru Join Date: Aug 2006 Location: AM-51, Deen Dayal Nagar, Gwalior, Madhya Pradesh, MP 474001, India Posts: 3418 Good Answers: 32	#2 In reply to #1 Re: Experimenting With High Frequency Transformers 05/27/2011 11:12 AM
	This project is under limited research grant and perhaps will let few master's degree engineers to get involved to generate information. Technology has potential for moving into commercial arena. Right now scope is limited to share information freely with who-so-ever wants to get involved. I will not know if anyone picks information and sells it out. Most of the technology generated in research has some degree of commercial aspects and this one is not exceptional but no one is selling here to anyone. I felt it is worth disclosing that this project has a research grant and we thus do not need any external funds. Now I think we can move to share information as that is the main aim of posting. Few experiments were conducted and transformers for 25kHz at 75% push-pull ON time were tested. Output power was about 1kW calculated from waveform and load but it is to be confirmed by high frequency CT.. __________________ Prof. (Dr.) Shyam, Managing Director for Sensors Technology Private Limited. Gwalior, MP474001, India.
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BertHickman Commentator Join Date: Mar 2007 Location: Chicago suburbs, USA Posts: 73 Good Answers: 21	#3 Re: Experimenting With High Frequency Transformers 05/28/2011 12:13 PM
	You may wish to explore using a resonant topology if you want mostly a sinusoidal output. __________________ Stoneridge Engineering - Wreaking Havoc with Electrons for over 40 Years!
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Shyam Guru Join Date: Aug 2006 Location: AM-51, Deen Dayal Nagar, Gwalior, Madhya Pradesh, MP 474001, India Posts: 3418 Good Answers: 32	#5 In reply to #3 Re: Experimenting With High Frequency Transformers 05/28/2011 10:49 PM
	The switching method used is push-pull with single transformer in class C mode right now and LC tuned filter in secondary are matched to the frequency to shape the waveform to near sine wave. In the primary, only snubber filters are used and power is switched at zero crossing. Two switching waveforms were tried. One at 25% duty cycle and another at 33% duty cycle. While lower power shown sine wave, at higher power it is turning into square wave and perhaps due to saturation of the core at 1kW power. Ferrite core of the transformer looks good only for about 400W for good sine wave so will increase the core size from 50mm x 50mm x 20mm E-core to 59mm type in next testing. Initially tried with IXYS MOSFETs and many were damaged in few seconds even though 12A rated X 3 were used together to fire each push-pull arm. Now changed to 40A 1200V IGBT and it looks that just X2 are able to drive each arm continuously. __________________ Prof. (Dr.) Shyam, Managing Director for Sensors Technology Private Limited. Gwalior, MP474001, India.
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ferquiza Power-User Join Date: May 2008 Posts: 380	#4 Re: Experimenting With High Frequency Transformers 05/28/2011 4:16 PM
	1kw? switching? what application?.-
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Shyam Guru Join Date: Aug 2006 Location: AM-51, Deen Dayal Nagar, Gwalior, Madhya Pradesh, MP 474001, India Posts: 3418 Good Answers: 32	#6 In reply to #4 Re: Experimenting With High Frequency Transformers 05/28/2011 10:51 PM
	Ultrasonics. __________________ Prof. (Dr.) Shyam, Managing Director for Sensors Technology Private Limited. Gwalior, MP474001, India.
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BertHickman (1); ferquiza (1); Shyam (3); TonyS (1)

You might be interested in: Transformers, Electronic Transformers, Telecom Transformers

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