How do we design a toroidal transformer?
Concerning the mouse and the control buttons
You can use the mouse for everything.
The menu control can also be activated by means of the Alt key and the control letter for the menu option (after pressing the Alt key, it is normally visible in a different color). Some important menu options can be activated by means of the F keys.
Here is a survey of all control keys:
Run RALE DESIGN System for toroidal transformers
After installation of the RALE Design System , you see the Rale Design System program group on-screen.
Click on the Toroidal Transformers bottom
After clicking on the Toroidal Transformers bottom, the main menu for the Toroidal Transformers Program will appear on-screen.
This is followed by the input mask on screen with your input data
Your last input file will be loaded into the input mask. Here, you can create your input or incorporate the input data from an input data file and thus achieve drastic acceleration in the procedure for filling-in of the input mask.
In the installation of the Rale Design System, a
RALE library of input data files has also been installed, with the
distinction between two groups:
Example: R1532A4.TR1 or R1533E.TR1
For all input data files, an ambient temperature
of 40oC has been used.
The input mask consists of 5 areas:
The 6 fields of the status line indicate, in
sequence, the core family, the core, the iron quality family, iron
quality, and the minimum and maximum values of the current input.
Key F1 plays an important part at this point, because each input field has a help text. Use ESC to quit on-line help.
The input fields which are marked * are values with a unit of quantity (V, A, Hz,...) or multiplication factors. The input fields with - are code values. These can be entered or selected via the Options menu.
Wires and steel
The input fields for Wire type (not wire size) and Steel are a minor exception in this instance and can be selected in addition to manual input via the Material/Wires/Fe menu or selected by means of keys F11and F12.
Core and bobbin unit
Using the menu option of Material/Cores or
key F9, you can select a core with a given bobbin or set up
your own preferred combination.
Core and bobbin are selected
Core and bobbin are incorporated from a single input data file
The core and bobbin are manually entered
Note 1 : If you change the core sizes Di, Da and H the program will show you the maximal, optimal sizes of the transformer Diw, Daw and Hw.
Note 2 : If you change the sizes of the transformer Diw, Daw and Hw the program will show you the minimal, optimal sizes of the core Di, Da and H.
Under this procedure, we have no further work to do on-line with regard to core selection.
Saving the input data file
Your input is COMPLETE! It is recommended that you save your input data into an input file.
Design is started via the Run/Start menu option or with key F4.
If you have not already selected a core, the program starts automatic search in accordance with one of your requirements from the core size as per your inputting, from the selected core data file.
The program starts searching at the first core of the core family and passes through to the last core in the family in sequence. You are invited to approve the first core which is adequately large for your application.
This is followed by the design operation. Note that there are 2 criteria of the optimizing: dT => temperature rise or dU => Regulation
Data page for winding
The continuation of the above screen illustrates the extensive display of the design results. Each designed value is allocated with an appropriate explanatory text.
If you should need further information, please locate the cursor on the size value and press key F1. This activates on-line help.
Press Key "1"..."9" to jump to the other screens or press F8 to print the calculated results :
If you are not satisfied with the results of design, you can :
Activate the Input/Test menu option or press key F5.
In the test mode you can test a designed transformer and manually change its parameters.
The input fields with the white background can be modified. For instance, if you want to change the wire size you have to move the cursor to the wire number:
Click the menu option Material/Wires or press F12 to open the list with the wires.
This is he current wire size
Select the wire size which you want and pres Alt-O or click OK
Re-design in the test mode is activated via the Run/Test menu option or by means of key F6.
(Alt-R and T or F6 only)
Help in test mode
In order to get on-line help in the test mode place the cursor where you need help and press F1
The printing is performed via the Output/Print menu option or by means of key F8. After activation of the print process, the data, totalling approx 16kB (3 pages), is printed on your printer. You can too save the results of design on your PC and load them and print out later. The procedure for saving of the designed data looks like this:
Saving of results of design
Saving of the designed data which you can load and print out later on the data page for the winding, is activated via the Output/Save menu option.
(Alt-A and S)Enter a name for the output file in which the designed data is to be saved.
This completes your design.
Quitting your RALE Design System for toroidal transformers
Select the Input/exit menu option or press key Crtl-F12 and then click on the Yes button.
In this context, we have just discussed the procedure for design of the toroidal transformer. There is extensive coverage of the technical aspect of design, within the design examples.