To all those responding to my query, I thank you very much. This discussion has been enlightening to say the least. Little did I realize making the transformer more efficient would cause so many questions and comments.
I want to add a follow-up to my earlier post to clarify one particular point. The design change to this transformer did not reduce the core area. In fact it increased it slightly. The original design was 180 mm o.d., 100 mm i.d., and 90 mm high. (as I recall it). The change was to decrease the i.d. of the core opening by 5 mm so it becomes 180 x 95 x 90 mm. This increases the core material by that small amount. The turns were decreased 5%. Not being a transformer guy, my guess is the turns were decreased to compensate for the core material increase or to help lower temperature, or both. The core is also annealed now. I had to look that one up. Annealing heats the metal up then cools it slowly in the furnace in order to make it less brittle. One other point is the mounting. The center of the toroid is potted and there is a bolt hole though it. This bolt is horizontal when installed in the product. There are neoprene pads, one on each side isolating the toroid from the two steel panels it is clamped between. The bolt draws it all tight. We are working to solve this puzzle, but the holidays will slow us down a bit. I let you know what we do as I can. Meanwhile, keep those cards and letters coming folks. Once again, thank you all and Merry Christmas! Regards, Scott Douglas [email protected] - This message is from the IEEE Product Safety Engineering Society emc-pstc discussion list. Website: http://www.ieee-pses.org/ To post a message to the list, send your e-mail to [email protected] Instructions: http://listserv.ieee.org/request/user-guide.html List rules: http://www.ieee-pses.org/listrules.html For help, send mail to the list administrators: Scott Douglas [email protected] Mike Cantwell [email protected] For policy questions, send mail to: Jim Bacher: [email protected] David Heald: [email protected] All emc-pstc postings are archived and searchable on the web at: http://www.ieeecommunities.org/emc-pstc
