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Rajesh, You've only partially defined the problem. Additional requirements are necessary before you can begin. These include the waveform shape (sinusoidal, square-wave? - how do you plan to drive your transformer?), operating frequency, and core cross-sectional area, material type, and manufacturer for your particular core. Based upon the primary current (20 amperes) and turns ratio (25:1), the secondary current looks like it will be quite high (500 amperes) - is your winding window for your existing core sufficient to handle the conductor size you'll need? There are a number of design tradeoffs that you'll need to make. For example, while using a higher operating frequency will allow you handle larger power in a smaller space, it will also places more stringent demands on core and conductor materials, insulation, and geometry. You may need to use Litz wire or copper foil to reduce skin effect and more expensive core materials in order to reduce losses at higher frequencies. These tend to drive up cost, especially if you are only making a single transformer. But lowering the frequency may cause you to need a larger core so that you can handle the same amount of power. Transformer design is straightforward, but it is not a trivial undertaking - you'll need to do a bit of studying. Following are some web-based sources that should help you learn more about how to design transformers. The first resource deals with general transformer design, while the other two deal with core selection and other aspects of ferrite power transformer design: Printed sources of information for transformer design include some of the following books. The following are still in print (but unfortunately they are not cheap!): A very readable and practical text is Eric Lowdon's "Practical Transformer Design Handbook". Although it's out of print, it is still available: Good luck and best regards, -- Bert --
: Dear forum members,
: I need to design a high freq. high power transformer.
: The specifications are: Primary voltage : 420Vpeak-peak
: Primary current : 20A
: Turns ratio : 25:1
: What kind of wire can I use for primaryand secondary ?
: I am planning to build this transformer at home.
: I have 100mm-wide UU cores. Howshall I proceed ?
: ... and also, i want the cost to be minimum ...
: Kindly guide me in designing this transformer.
: Thanks in advance.
: -Rajesh.
:
http://members.tripod.com/~schematics/xform/xformer1.htm
http://www.mag-inc.com/pdf/twc-s3.pdf
http://www.acs.comcen.com.au/ferrites.html
http://books.mcgraw-hill.com/cgi-bin/pbg/0070212910.html
http://www.bookworkz.com/construction/power_electronics/047181976X.html
http://www.magnaphysics.com/transfomer%20and%20inductor%20design%20handbook.htm
http://www.amazon.com/exec/obidos/ASIN/0830632123/processassociate/103-9583310-4218251
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