Calculations For Design Parameters of Transformer

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Calculations for Design Parameters of Transformer

OCTOBER 14, 2016 ASAD ULLAH (HTTP://ENGINEEREXPERIENCES.COM/AUTHOR/ASAD-ULLAH)
108 COMMENTS (HTTP://ENGINEEREXPERIENCES.COM/DESIGN-CALCULATIONS.HTML#COMMENTS)
Table of Contents 
Design Parameters of Transformer

For Quick review and summary of Calculations, see the tables at the end of this article. (Table 1)
(https://lh3.googleusercontent.com/-
UqSM4KW7kTo/Vk1qeGGs9EI/AAAAAAAAAlc/5XNn4WQtgck/s512-Ic42/primary.JPG) (Table 2)
(https://lh3.googleusercontent.com/-ZkfU3uUO96s/Vk1qeGyiVqI/AAAAAAAAAlg/tS1YlVeqW2M/s576-
Ic42/secondary.jpg) For better understandings, go through the following steps for calculations. Make
sure you have knowledge of Basics of Transfomer
(http://engineerexperiences.com/transformer-basics.html)
Design Parameters
For designing a transformer, we need:
1. Power rating
2. Voltage levels (primary and secondary)
3. Currents on both sides
4. Primary and secondary coils wire diameter/size
5. Iron Core area
6. Numbers of turns (primary and secondary)
We are going to design a 50 VA step down transformer of 230V to 12V. Necessary calculations
along with formulae are given below in details:
As we are going to design small transformer (of small power rating) so we are neglecting core and
copper losses as they doesn’t matters in small transformers
(http://engineerexperiences.com/category/transformer)and seriously considered in designing power
transformers (high power rating transforms).
Calculations:
1. Core Calculations:
Calculate area of core (central limb) by using following formula:
Ai = 1/4.44xfxBmxTe
Ai= area of core

F= operating frequency
Bm= magnetic ux density
Te= turns per volts (http://engineerexperiences.com/transformer-design-turns-per-
volts.html)
(for derivation of this formula Click Here (http://engineerexperiences.com/turns-per-volts-
transformer-design.html))
ASSUMPTIONS:
So, we know the frequency of the power system. We need magnetic ux and turns per volts. For
designing a small transformer magnetic ux density is averagely taken as 1 to 1.2.
By putting values we will get the area of core.
Current density of copper wire is taken as 2.2 A / mm2 to 2.4 A/ mm2 (approximately).
So, putting values
F= 50 hz
Bm = 1.2 wb/m2
Te = 4 (turns per volts)
As, we are going to design a practical transformer
(http://engineerexperiences.com/category/transformer)so we must consider the core
available in market. The standard Bobbins available in market practically is 1”x1”, 1.25”x1.5”,
1.5”x1.5” and so on. We took nearest core area available to our calculation. We took bobbin of
2.25 inch2 (1.5”x1.5”) or 0.00145161 meter square. We have the core area. We can calculate
turns per volts using this area by following:
Putting f=50 hz; Bm = 1.2 wb/(m^2); Ai= 0.001451 m^2, we got:
So, Turns per volts are 2.6 Turns per volts. (http://engineerexperiences.com/turns-per-
volts-transformer-design.html)
Primary Winding Calculations
Primary voltage = Vp = 230 V

Primary current = I1= VA / Vp = 50 / 230 = 0.218
Let transformer we are going to design is 95 % efficient so,

I1 = VA/ (efficiency x Vp) = 0.23A
Primary Current = 0.23 Amp (approx.)
Number of Turns:
Total number of turns = turns per volts (http://engineerexperiences.com/tu

= 2.6 x 230
N1 =
= 600 turns (approximately)
Size of Conductor:
As we know that
As, for copper the current density is taken as 2.3 A per mm square So, for area of copper
conductor

From the standard American wire gauge table, we can choose wire of the same thickness. It can
be seen that it comes out that required primary side wire is of 27 gauge which can conduct
required current. (for AWG table Click here (http://www.powerstream.com/Wire_Size.htm))
Selection of wire can also be done by calculating primary current and by cross match the
standard table of copper wire according to their current handling capabilities.
Secondary Winding Calculations
Secondary voltage = Vs = 12 V
Secondary current = Is = VA/ Vs = 50 / 12 = 4.2 Amp (approx.)
From the standard copper wire, table it can be seen that wire of this thickness is of 15 gauge. So
for secondary winding we need 15 gauge wire.
So,
Secondary Wire =15 AWG
Number of Turns:
Number of secondary turns = turns per volts (http://engineerexperiences.co
N2 = 2.6 x 12 = 32 turns (approx.)
Weight Estimation of Windings
For weight calculations, following steps will be followed:
1. Approximate length of copper wire = perimeter of bobbin x number of turns

2. Cross sectional Area of copper conductor
3. Volume = Approximate length x Cross sectional area
4. Mass = density of copper x Volume
Density of copper = 8960 kg/ m3
Primary side:
Perimeter of bobbin = (1.75 x 4) = 7 inch = 0.1778 m
So,
Length of one turn = 0.1778 m

Total length of all turns of primary = L1
L1 = (length of one turn) x(total number of turns of primary)

L1 = 0.1778 x 600
L1 = 106 m (approx.)
As,
area of primary conductor = 0.1 mm2
= (0.1 x 10 ^ -6) m2
Volume of copper wire = area x length
And density of copper = 8960 kg/ m3
So,
So we need approx. 100 grams of 27 gauge wire.
Secondary winding weight:

Perimeter of bobbin = (1.75 x 4) = 7 inch = 0.1778 m
So,
Length of one turn = 0.1778 m
Total length of all turns of Secondary
= L2 = length of one turn x total number of turns of secondary
L2 = 0.1778 x 32
L2 = 6 m (approx.)
As,
area of primary conductor = 1.83 mm2 = (1.83 x 10 ^ -6) m2
Volume of copper wire = area x length
So, we need approx. 100 grams of 15 gauge wire.
So, from above calculations we can summarize in following table:

(https://i2.wp.com/lh3.googleusercontent.com/-
UqSM4KW7kTo/Vk1qeGGs9EI/AAAAAAAAAlc/5XNn4WQtgck/s51
2-Ic42/primary.JPG?ssl=1)
Table 1: Calculation for primary side
———————————————————————————————————————
(https://i0.wp.com/lh3.googleusercontent.com/-
ZkfU3uUO96s/Vk1qeGyiVqI/AAAAAAAAAlg/tS1YlVeqW2M/s576-
Ic42/secondary.jpg?ssl=1)
Table 2: Design Summary for Secondary of transformer design
At this point you have done the Calculations and you have the characteristics of transformer
components. Now, for making in hard form, see few easiest steps of hardware
implementation of calculations (http://engineerexperiences.com/hardware-design-.html):
Here is another article for transformer core optimization using Genetic Algorithm
(http://engineerexperiences.com/transformer-core-optimization-using-genetic-algorithm-
ga.html) – a heuristic method of optimization.
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108 thoughts on “Calculations for Design Parameters of Transformer”
Anonymous says:
May 1, 2019 at 5:22 pm (http://engineerexperiences.com/design-calculations.html#comment-
9848)
Sir.the value of current density is not internationally.that u put.
Reply →
noxuz says:
February 22, 2019 at 1:34 am (http://engineerexperiences.com/design-
calculations.html#comment-7004)
Hi, you are not taking into account the total mass of the core needed due to it’s
saturation of magnetic ux Bm
Reply →
Pingback: Calculations for Design Parameters of Transformer | Engineer Experiences –
zliberate (https://zliberate.wordpress.com/2019/02/21/calculations-for-design-
parameters-of-transformer-engineer-experiences/)
milkesa (http://education566174663.wordpress.com) says:

December 26, 2018 at 2:15 pm (http://engineerexperiences.com/design-
I was looking for formulas to calculate transformar for example i have transformar
but i want to rewind it with di erent input and output ac. i couldn’t get formulas
for it please
Reply →
BASANT KEWAT says:

November 27, 2018 at 3:58 pm (http://engineerexperiences.com/design-
nicely engineered Design e ort
Basant
Reply →
M Adnan says:
what is the formula to calculatre te area of auto transformer?
Reply →
G. says:
September 27, 2018 at 12:17 pm (http://engineerexperiences.com/design-
You give formula parameters to use that do NOT make any sense then you solve
an equation BUT DO NOT Explain how you derived at simpli ed variable sub totals
and then give a resultant. For example: F= 50 hz
Bm = 1.2 wb/m2
Ai= 9.384 × 10-4m 2 ~1.45 inch sq. Really? Are you assuming your viewing
audience has taken advanced algebra or is space as a premium you can’t explain
how you did this or are you just too damn lazy to explain how you got there?
AS the saying goes —-it’s like listening to one engineer talk another.
Reply →
Mircea says:
There is a formula in “1.Core Calculations.” He gives you values for all

variables except one. Then he computes the unknown one. I learned to
do that when I was 3rd grade in school. Where do you come from?
Reply →
Anonymous says:
July 16, 2018 at 12:29 pm (http://engineerexperiences.com/design-calculations.html#comment-
515)
hello sir can you make also a calculation for toroidal transformer?
Reply →
Asad Ullah says:

July 28, 2018 at 9:36 pm (http://engineerexperiences.com/design-
Unfortunately, toroidal transformer calculations are not available

currently.
Reply →
g.satheeshkumar says:
December 4, 2018 at 10:58 am
(http://engineerexperiences.com/design-
sir, you are put the value of Te=4, please explain this
brie y. and next stage u derive this as 2.6 turns. how u
adapt the Ai value with this formula Te=1/4.44fABm.
Reply →
Asad Ullah says:

December 19, 2018 at 1:49 pm
Te=4 is not standard but it is kind of

standard for small transformer design.
Ai is taken according to the standard
bobin sizes available in market. so, by
using that size, we can calculate the
turns per volts.
Reply →
g.satheeshkumar says:
December 4, 2018 at 11:09 am
or Te=4 is it standard for all type of step down

transformer
Reply →
Anonymous says:
514)
Hello sir, can i apply this on SWG magnetic wire? We dont use here in philippines
AWG table. There is a big di erence on AWG ang SWG
Thank you
Reply →
Asad Ullah says:
You can calculate the current in each winding and according to

maximum current, you can choose wire from wire gauge table of
your ease.
Hope you got your answer.
Reply →
Billy Bob says:

August 31, 2018 at 9:42 pm
If i sent you a nameplate from a transformer do you

think you could estimate the copper content of the
transformer with much accuracy?
Reply →
Asad Ullah says:

September 3, 2018 at 12:13 pm
you can check by yourself according to

power rating.
I can give it try. you can send on email
address.
engineerexperiences@gmail.com
(mailto:engineerexperiences@gmail
.com)
Reply →
Anonymous says:
No di erence inche to mm conversion.
Reply →
Den says:
June 18, 2018 at 8:46 pm (http://engineerexperiences.com/design-calculations.html#comment-
495)
Anyone knows why the e ciency e ect is only applied on primary current ?? How
about the secondary current?
And also what should I do if I require 50% margin for core area? Why is also the
perimeter value is using 1.75 instead of 1.5??
Reply →
Asad Ullah says:

June 24, 2018 at 5:21 pm (http://engineerexperiences.com/design-
primary side current is responsible for induction in secondary side

as well as losses in core for magnetization and de-magnetization.
That’s why primary side current is considered for e ciency.
Yes, the perimeter should be 1.5 instead of 1.75
Reply →
Asad Ullah says:

1.75 is not wrong (to some level). As we are not taking other
parameters into account for winding. So, Doesn’t matter here (to
this level of design)
Reply →
Olajide Taiwo says:
June 15, 2018 at 5:34 am (http://engineerexperiences.com/design-calculations.html#comment-
493)
Thank you for your design of this single phase transformer, all your explanations
are very clear and straight to the point.
It will be very nice if you could please let us have also a design for a three phase
transformer.
Thanks a lot.
Jide T.
Reply →
Ebenezer Smart says:

June 13, 2018 at 11:30 am (http://engineerexperiences.com/design-
thanks a lot sir,

sir, for someone to design a transformer of 10,000 watts, what size of wire will be
needed, cause according to your formula the value am getting is excess and I
couldn’t see the value i got in the wire Gage data sheet
Reply →
Asad Ullah says:

As mentioned in article, this method is good and suitable for

designing small transformers. For high power transformer, other
factors a ects too.
Anyways, just as a tip: for current handling you can use copper
strips for winding and use multiple parallel paths for same
winding. (i.e. multiple parallel conductor bars to handle. If a bar
handles 10Amps max, you can use two parallel bars for 20Amps.)
Again, it is just a tip. use on your own risk.
P.S: But the use of strips are valid.
Reply →
Mircea Bujor says:
June 4, 2018 at 7:55 pm (http://engineerexperiences.com/design-calculations.html#comment-
490)
Hi, Is it ok to use 4A/mm2 current density in a toroidal transformer? I understand

your design is for square transformer.
Reply →
Asad Ullah says:

These calculations cum assumptions are for designing of soft

silicon steel based core transformers. As far i know, torodial
transformers have core of other iron, cobalt, manganese alloy. So,
i can’t comment about current density for that currently.
Anyhow, That cores requires less energy to energize with higher
current densities to handle… exact gure, i can’t comment at
moment.
Reply →
Abdul Samad says:

May 28, 2018 at 2:17 am (http://engineerexperiences.com/design-calculations.html#comment-
484)
Most helpful article.I appreciate your work.Great sir
Reply →
Vijay Varsani (https://plus.google.com/107104542531903722132) says:

480)
2×5=10″ a\ 60000 fd \ 50hz\ 4.44 gus equatane is t=100000000/4.44*hz*fd*a …. so

your t=0.75v
so if you wont 90v taping so 90*0.75=67.5t if you wont 230 v so 230*0.75=172.5t
Reply →
Tebogo says:
May 18, 2018 at 12:34 pm (http://engineerexperiences.com/design-
Sir help me understand how to do calculations for transformer power rating.How

do you decide on the size of your transformer in kVA or MVA?
Reply →
Asad Ullah says:

Power rating of transformer depends on the use of transformer.

VA, kVA, MVA depends on your application of transformer.
Reply →
Tebogo says:
May 18, 2018 at 12:17 pm (http://engineerexperiences.com/design-
Sir what is the shape of this bobbin and which side are you referring to since we
used a 1.5inchx1.5inch bobbin?
Reply →
Asad Ullah says:

http://engineerexperiences.com/hardware-design-.html
(http://engineerexperiences.com/hardware-design-.html)
hope this link will help you.
Reply →
Faizan Ahmad says:

476)
its very help full article.
Reply →
Anonymous says:
475)
GREAT sir!
Reply →
Virendra Singh says:

474)
Above Calculation based on the Value Te=4 Turn Per Volt. What is
bene t/drawback if we choose a big/small size of Bobbin
Reply →
Asad Ullah says:

bobbin size is, somewhat mechanical parameter which decides

size of your transformer. Greater size bobbin will only increase
cost and weight of transformer material. Smaller bobbin will not
be able to hold enough steel core for required power transfer
(from primary to secondary).
Reply →
Munawar says:
April 15, 2018 at 7:36 am (http://engineerexperiences.com/design-calculations.html#comment-
454)
is it possible to put a 500kva transformer winding in another 500kva transformer

core ????
Reply →
Asad Ullah says:
April 16, 2018 at 11:09 pm (http://engineerexperiences.com/design-
if both are designed to serve the same purpose, there is nothing

wrong replacing one’s winding with other’s.
Reply →
VICTOR AGBEBI says:

April 2, 2018 at 1:20 pm (http://engineerexperiences.com/design-calculations.html#comment-
448)
I need to construct a 1.5kVa transformer with 12-0-12 primary and 220V

secondary. What is the wire guage needed and number of turns.kindly help
Reply →
Asad Ullah says:

Just follow the formula given above. Nothing will change except
the power ratings. Two windings of same ratings with be there on
secondary side.
Reply →
Freedom Philip Lachica

(https://plus.google.com/117006796292632589202) says:
March 22, 2018 at 9:09 pm (http://engineerexperiences.com/design-
sir, can the size of the copper wire a ect the number of turns? if it can, how so?
because, as how I understand the solution above, it seems it does not a ect.
sorry, I’m a newbie. and moreover, we would like to design a 15VA, 220/30 V single
phase transformer. we already have 1.25″x1.25″ bobbin and a number 25 gauge
wire. how can we determine the number of turns?
Reply →
Asad Ullah says:
size of copper wire is e ected by the current. Number of turns on

other hand, related to voltage (actually to the generation of
magnetic ux and ultimately to voltage generation). So, as in
article, number of turns are calculated according to voltage
requirement and copper wire gauge is calculated by current
requirements. Hope you got your answer.
Reply →
Santosh says:
March 22, 2018 at 9:12 am (http://engineerexperiences.com/design-
Sir mai 5kva 8no. Core me(input=90v – 300v) automatic stabilizer banana chahata
hu to sir mai kaise calculate kr k turn nikalu.
Reply →
Asad Ullah says:

Calculate turn and wire gauge for each voltage level at secondary.
Obviously, you want some steps between these voltage levels so
there will be as much number of windings as the number of steps
of voltages of secondary. Then by the use of relays, voltage sensor
and micro-controller programming, you can make this automatic.
Reply →
Santosh says:
Sir mere paas 7no. core(2″ * 5″) hai to sir mai (input= 90v-300v) tk ka automatic
voltage stabilizer ka coil banana chahata hu.
to sir mai kaise calculate kr k turn nikalu.
Plzz bataeye.
Reply →
Anonymous says:
where is the EI iron core detail
Reply →
Asad Ullah says:

http://engineerexperiences.com/transformer-basics.html
(http://engineerexperiences.com/transformer-basics.html)
Hope you can nd enough to understand here.
Reply →
Guptan Veemboor says:

Thanks for this simple explanation. I am an eighty year old man retired and going
through these things just to while away the time. I have some engineering
background. But have forgotten everything- practically. Thanks once again.
Regards, Guptan
Reply →
Ralph says:
February 18, 2018 at 7:54 pm (http://engineerexperiences.com/design-
Does this applicable for multi-winding transformers with di erent voltage and
current rating in every windings.
Reply →
Asad Ullah says:

Yes, if you calculate each winding di erently.
Reply →
nadeem butt says:

sir , what is pulse transformer & how to make it .for fence charger input 350-400
volt & output 5000-9000 volt in pulse with 8 mill ampere
Reply →
ndayisaba theoneste says:

January 17, 2018 at 3:51 pm (http://engineerexperiences.com/design-
i kneed your helper i want to design a step up transformer of 150VA primary

voltage is75v and secondary voltage is 220V
Reply →
Asad Ullah says:

January 20, 2018 at 11:45 am (http://engineerexperiences.com/design-
Calculations will be same as said in article. just change the voltage

levels and you’ll get currents and nd number of turns and wire
gauges accordingly.
Reply →
Anonymous says:
I want to learn about electrical experience more and more.
Reply →
Nooman Khan says:

how to nd the bobbin size from power (VA) rating of transformer ?
Reply →
Asad Ullah says:

Actually, VA rating does not have direct a ect on bobbin size. It

depends on maximum ux density, number of turns and material
for core. In this article, we are using laminated stripped iron core
and taking standards for maximum ux density and number of
volts per turns.
I hope you get your answer.
Reply →
Abhilash Routray says:

October 11, 2017 at 9:23 am (http://engineerexperiences.com/design-
F= 50 hz
Bm = 1.2 wb/m2
How did u get te =4 turns per volt?
Reply →
Asad Ullah says:

The turns per volts are assumptions is constant and almost

standardized for designing small transformer.
Actually, magnetic ux density is standard and turns per volt are
calculated using that value. You can check derivation on an article
linked below:
http://engineerexperiences.com/turns-per-volts-transformer-
design.html (http://engineerexperiences.com/turns-per-volts-
transformer-design.html)
Reply →
inayat says:
October 7, 2017 at 1:23 pm (http://engineerexperiences.com/design-
Sir kindly answer my question

I made a transformer which have primery winding is 220 turn(18 swg wire 1kg)
and secondary turn is 22 turn(10 swg 650gram) now the input voltage is 210 volt
and output is 18 volt
bobin size is ( 6inch×3inch) how much current given in output ?????
Plz answer my question
Reply →
Asad Ullah says:

As per calculations, you have current ratio of 1:10 (primary to

secondary). Now, as you have 18 SWG so it can have max of
3Amp. So, it can have 3amp to primary and almost 25~30Amp at
secondary (at max).
Reply →
PHIWE (http://engineerexperiences.com) says:
I AM CONFUSED BY THE VERY FIRST FORMULA BECAUSE YOU SAY THAT Bm IS

MAGNETIC FLUX_Phi_(Wb) AND YET YOU SUBSTITUTE THE MAGNETIC FLUX
DENSITY(Wb/m^2) HOW SO???
Reply →
Asad Ullah says:

It is actually magnetic ux density, no matter the nomenclature in

the article it is still magnetic ux density.
Reply →
Pingback: How to calculate Toroidal Core Maximum VA capacity | Page 4 | Physics

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Adnan khan says:

Sir ma transformer banana chatha ho mera pas iron core pare ha his ma
3.8cm5cm ha moja wire no bata dena tarn me tadad be secondary or prembry
Dino ma ma an pard ho koch moskil aya gee please ap mer madad kro thanks
Reply →
Asad Ullah says:

You want transformer of which ratings ? Wire size depends on
power ratings of transformer.
Reply →
Robert Ross (http://www.idioms4you.com) says:

September 1, 2017 at 2:14 am (http://engineerexperiences.com/design-
Asad, This page is absolutely fantastic. Thank you very much. In the above, “1.75 is
the length of one side of the bobbin.” In the example on this page, I understood
that a standard size of 1.5 inches by 1.5 inches was used for the example
calculations. Could you please help me understand where the 1.75 inches is
derived from?
Reply →
shivam patel says:

August 22, 2017 at 5:17 pm (http://engineerexperiences.com/design-
Sir,I made a transformer 24V 3A,72VA operated in 220V which heated more
without load..and output is accurate, bobbin area is 10.26sqcm , primary turn 937
, turn per volt 4.26, secondary turn 106 ,primary wire gauge 28, secondary wire
gauge 19 can anyone please explain why so heated?????thanks
Reply →
Asad Ullah says:

September 1, 2017 at 8:34 am (http://engineerexperiences.com/design-
Heating could be due to low quality core material or loose binding

of core (air between core stampings) as a lot of power is being lost
in it. Use laminated core stamping for core and hard bind them to
avoid losses.
Reply →
Bobby says:
pls for large transformer power like 6kva, how will i get the value of ux density
(Bm)
Reply →
Amabo says:
By using the same perimeter value for both primary and secondary, you implicitly
assume that windings are side by side (split bobbin) rather than one over the
other. Standard practice is to use not perimeter but mean length of term (MLT),
thus the stated wire lengths are too long. The winding area is not lled 100%
because the wire is round and has air included in the winding cross section.
Standard practice is to use a ll factor which tends to be around 60% when
winding technique and insulation thickness are included. This a ects the choice of
wire gauge to t the cross section. From wire length and gauge the next step is to
calculate resistances from which the voltage drops can be known, noting that AC
resistance will be somewhat greater than DC resistance. Then the design can be
iterated to compensate.
Reply →
Asad Ullah says:

Yes you are right. I am aware of ‘mean length per turn’, ‘window
e ective area’, resistance of winding, core geometrical constants
and many more factors according to which transformer is
designed. Here, we have designed small transformer and with
compensation factor, some parameters are neglected and some
are included in compensation factor.
Thank you for your considerations. Design calculations according
to all these factor included will be available soon.
Reply →
behzad says:
July 29, 2017 at 3:32 am (http://engineerexperiences.com/design-calculations.html#comment-
291)
as i gured out, all the formulas work only for ac input. what about a rectangular
pulse? should i use Fourier expression o voltage and then nd EMF equation?
Reply →
Faisal Javaid says:

281)
most help full artical or information….welldone

Asad bhai aap transfomer ka temprature rise nd out kr skty hain to kinly mari
kuch help kr dain aur L.T ,H.T eddy loss formula k bary ma b bta dain….Thanks
Reply →
Anonymous says:
277)
How to make welding transformer?
Reply →
adeh augustine says:

272)
Mr Asad thank you for your explanation. Please I have a problem similar to this…
am asked to nd the parameters of a Transformer core (shell type) such as
height(H), diameter(D), width(W), width and length of the window slot(Ws). Haven
being given insulation thickness as 2mm, V=220/18v, P=450W, power factor as 0.8,
window factor as 0.3, maximum ux density(Bm=0.42T), F=50Hz, k=1.2.
Please how can I go about this.
Reply →
Mohammed Idrees says:

265)
What is current density for aluminium? Is the current density value is xed?
Reply →
Asad Ullah says:
Yes, every material (conductor) have its constant current density

as it is property of material. Aluminum has current density of
around 0.5 A/mm^2
Reply →
Mohammed Idrees says:

264)
How to design k rated transformer
Reply →
Stanley Izebhokhae says:

263)
bobbin of 2.25 inch2 (1.5”x1.5”) or 0.00145161 meter square. how dis you get
0,00145161!
Reply →
Asad Ullah says:

2.25 inch square = 0.001455161 meter squares

it’s simple area units conversion.
Reply →
syed says:
June 13, 2017 at 10:04 am (http://engineerexperiences.com/design-
asslamwalkum sir can i u please explaine me the core calculation of CT
Reply →
Asad Ullah says:

CT is a transformer with very low voltage drop at primary side and

it is stepped up for measurement. Core calculation for small CTs is
almost same as other transformers but for very small sized CTs,
ferrite core is used which need di erent set of calculations.
Reply →
Kushal Trivedi says:

April 30, 2017 at 1:11 am (http://engineerexperiences.com/design-calculations.html#comment-
232)
Respected sir,how we nd the laminations size if it is NOT C.R.G.O. IT IS C.R.N.G.O
Reply →
Priyanka Naik says:

230)
Thank you for explaining the design of transform. I have one confusion that
Perimeter of bobbin=1.75 * 4 you have taken but 1.75 where it comes from???
Reply →
Asad Ullah says:

1.75 is length of one side of bobbin. To calculate length of one

complete revolution of wire around bobbin it is multiplied by 4.
Reply →
Syed Hedayat Hussain Zaidi says:
217)
Dear Mr. Asad-ullah Sahab. Your Article is very informative and help full. thanks
for sharing it. Regards, May Allah live you long..
Reply →
Idrees says:
212)
How to choose ux density? Whether it wil vary for 3 phase transformers?
Reply →
Akos says:
When you calculate the core area you assumed Te = 4 (turns per volts) but it was
not clear where this number 4 comes from. In other calculations the core area is
proportional to the squareroot of VA and approximated as Ai = 1.152*sqrt(Output
voltage x output current) = 1.152*sqrt(50VA) = 8.146 cm^2=8.146*10^-4 m^2 and
then using this Ai value the turns per volt is calculated Te = 1/(4.44AiBf) = 1/(4.44 *
8.146*10^-4m^2 * 1.2T * 50Hz) = 4.6 turns per volts which is close to 4 that you
assumed. So actually the turns per volts come from the area and not in the other
way because the are comes from the VA. So we don’t have to assume anything
because everything comes from somewhere.
Apart from this your work is nice. That was the only thing that was not
understandable and i had to look it up. Thanks for your post.
Reply →
Asad Ullah says:

That’s good thing you took interest and did research in this. But if
you look into literature of transformer design, some parameters
are constant for speci c core size and speci c material. You can
nd standard tables in many books which give you constant
values for calculated core sizes. This 4 turns per volt is from
standard table for small transformer design calculation listed in
Book by “R.K Agarwal” under the title of ” Principles of Electric
Machine Design”
Reply →
p tirupathi rao says:

for design purpose how much power factor will take for distrubution transformer
Reply →
Asad Ullah says:

For designing a transformer, power factor is not a thing to

consider as it depends upon load on transformer. This is one of
the important reasons that transformer ratings are in VA (or kVA
or MVA).
Reply →
Yilliang Peng (http://www.epe.com.au/maintenance-service/rewinds/)

says:
Thank you so much for explaining the parameters of transformers so precisely.

My wife was trying to gure out the area of the core; however, did not understand
which formula to use. This information de nitely makes it easy for us to just plug
in our information — thank you! We did not know that you could just assume the
transformers magnetic ux. Thank you again for the information!
Reply →
dhanasekar S says:
NEED 3 PHASE LAMINATED TRANSFORMER CORE WEIGHT CALCULATION

FORMULA IN SIMPLE METHOD..?
CAN U PLS HELP ME….?
Reply →
Asad Ullah says:

These calculations are for single phase transformer design. For 3

phase transformer, calculations and formulas are di erent. (this
article will be available soon)
You can design three phase transformers by connecting three
single phase transformers in star. (I personally designed and used
it). During connections you must take into considerations phase
sequence of all transformers.
Reply →
Almas (http://engineerexperiences.com/design-calculations.html)
says:
‫ﻣﺤﺘﺮم اﺳﺪ اﻟﻠﮧ ﺻﺎﺣﺐ‬

‫آج ﮐﻞ آﺋﺮن ﮐﻮر ﮐﯽ ﺑﺠﺎﺋﮯ ﮔﺮﯾﻔﺎﺋﯿﭧ ﮐﻮر ﮐﺎ اﺳﺘﻌﻤﺎل ﻋﺎم ﮨﻮرﮨﺎ۔ اﻧﺮﺟﯽ ﺳﯿﻮر ﻣﯿﮟ ﺟﻮ ﮐﻮاﺋﻞ ﮨﻮﺗﯽ ﮨﮯ اس ﺳﮯ‬
‫ ووﻟﭧ ﭨﺮاﻧﺴﻔﺮ ﻣﺮ ﺑﻨﺎﻧﺎ ﮨﮯ ﮨﮯ۔ ﮐﯿﺎ آپ ﻣﯿﺮی ﻣﺪد ﮐﺮ ﺳﮑﺘﮯ ﮨﯿﮟ؟ اﻟﻤﺎس ﺷﮩﺰاد‬12 ‫ﻣﯿﮟ ﻧﮯ اﯾﮏ‬
Reply →
Asad Ullah says:

Yes! some times graphite core transformers are used in high
frequency applications. Its not something you can generalize
about “going out” of iron core transformers.
For that transformers use same calculations for wire of primary
and secondary and calculate total area covered by winding
according to which you can nd out window are and nd graphite
core of that size.
Reply →
Almas
calculations.html) says:
February 7, 2017 at 12:02 pm
Asad Ullah! Thank to reply. you can guide me further

to make step down transformer using ferrite core or
give me any link with will be informative for me?
Reply →
Parag rekhi says:

I want calculations for low watts . Ma transformer is pri 220v /sec 1000v and
current is 50 ma .
Second transformer is pri 400v sec 5 v and current is 5 ma …can you help me
Reply →
Asad Ullah says:

Calculations for the wire would be same as for others. If you don’t
nd wire of your desire rating, use smallest ( say 30 AWG wire) to
wound your transformer. Your rst transformer is of course falls
in category of high voltage so lamination precautions must be
followed. Likewise, you can design second transformer.
Reply →
loganathan says:
hi… thank u for this article. upto which power rating core & copper losses r
neglected..
Reply →
Asad Ullah says:

Mostly, for Calculation of small transformers core losses are

neglected (mostly small transformer are considered up to 1000
VA).
However, plus minus 5 percent of turns of secondary winding is
added to overcome losses or get full voltage in full load
conditions.
Reply →
Andrew says:
December 23, 2016 at 3:13 am (http://engineerexperiences.com/design-
Hi, thank you for your article. On the core calculations section, could you explain
where you got the 4 turns per volt from that is needed to plug into the equation to
calculate the core area. Also, in the same equation, the constant 4.44 – what does
this represent? Thank you
Reply →
Asad Ullah says:
December 25, 2016 at 8:55 am (http://engineerexperiences.com/design-
For design of small transformer some assumptions have to made.

Turns per volts here are from a standard table of designing
transformer. (you can study it in book “Principles of Electric
Machine Design by R.K Agarwal” or any transformer design book).
This is according to transformer type and rating.
4.44 is constant in equation of turns per volts comes while
deriving this equation with help of fundamental equations.(click
link below for detail derivation).
http://engineerexperiences.com/turns-per-volts-transformer-
design.html (http://engineerexperiences.com/turns-per-volts-
transformer-design.html)
Hope you get your answer.
Reply →
nervic says:
4.44 comes from the rms formula derivation.
Reply →
TYLER BROOKS says:

Hey just wanted to say thanks you for all of these great articles! They read very
very well and you’ve covered all of my questions.
Reply →
Md Kawser Ahmed (https://plus.google.com/104970073673962513929)

says:
Great… Thanks.
Reply →
ishtiaq says:
October 27, 2016 at 10:59 pm (http://engineerexperiences.com/design-
At 60 hz frequency what will be ux density
Reply →
Asad Ullah says:

As per formula given in start of article, ux density and frequency

are inversely related. But, normally in designing ux density is
taken constant (as ux required is constant and area is constant).
So, if frequency changes the compensation is made on voltage
side. i.e. transformer will be designed accordingly with voltages.
but in small transformers such parameters are neglected mostly.
(but if you want to, Bm will be constant and voltages will be
changed.) P.S: sometimes tolerance voltage compensate this
change.
Reply →
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Calculations For Design Parameters of Transformer - Engineer Experiences

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Design Parameters of Transformer

For designing a transformer, we need:

Calculate area of core (central limb) by using following formula:

Ai= area of core

Primary Winding Calculations

Primary voltage = Vp = 230 V

Let transformer we are going to design is 95 % efficient so,

Total number of turns = turns per volts (http://engineerexperiences.com/tu

Secondary Winding Calculations

Secondary current = Is = VA/ Vs = 50 / 12 = 4.2 Amp (approx.)

Secondary Wire =15 AWG

Number of secondary turns = turns per volts (http://engineerexperiences.co

N2 = 2.6 x 12 = 32 turns (approx.)

Weight Estimation of Windings

For weight calculations, following steps will be followed:

1. Approximate length of copper wire = perimeter of bobbin x number of turns

Perimeter of bobbin = (1.75 x 4) = 7 inch = 0.1778 m

Length of one turn = 0.1778 m

L1 = (length of one turn) x(total number of turns of primary)

And density of copper = 8960 kg/ m3

So we need approx. 100 grams of 27 gauge wire.

Secondary winding weight:

Length of one turn = 0.1778 m

Total length of all turns of Secondary

= L2 = length of one turn x total number of turns of secondary

Volume of copper wire = area x length

So, we need approx. 100 grams of 15 gauge wire.

So, from above calculations we can summarize in following table:

Table 1: Calculation for primary side

Table 2: Design Summary for Secondary of transformer design

Taser Gun using 555

POSTED IN: ARTICLE (HTTP://ENGINEEREXPERIENCES.COM/CATEGORY/ARTICLE), DIY

← Hardware Introduction of Transformer Hardware Implementation of Transformer

108 thoughts on “Calculations for Design Parameters of Transformer”

Sir.the value of current density is not internationally.that u put.

milkesa (http://education566174663.wordpress.com) says:

BASANT KEWAT says:

nicely engineered Design e ort

what is the formula to calculatre te area of auto transformer?

There is a formula in “1.Core Calculations.” He gives you values for all

Asad Ullah says:

Unfortunately, toroidal transformer calculations are not available

Asad Ullah says:

Te=4 is not standard but it is kind of

or Te=4 is it standard for all type of step down

You can calculate the current in each winding and according to

Hope you got your answer.

Billy Bob says:

If i sent you a nameplate from a transformer do you

Asad Ullah says:

you can check by yourself according to

No di erence inche to mm conversion.

Asad Ullah says:

primary side current is responsible for induction in secondary side

Yes, the perimeter should be 1.5 instead of 1.75

Asad Ullah says:

Ebenezer Smart says:

thanks a lot sir,

Asad Ullah says:

As mentioned in article, this method is good and suitable for

Hi, Is it ok to use 4A/mm2 current density in a toroidal transformer? I understand

2×5=10″ a\ 60000 fd \ 50hz\ 4.44 gus equatane is t=100000000/4.44hzfd*a …. so