How to reduce copper loss and iron loss of transformer

1. Choose lower current density;

 

2. When the copper loss is significantly higher than the iron loss, use it with caution;

 

3. The main methods include reducing the diameter of copper wire (not reducing the total cross-sectional area), increasing the adjacent surface of primary stage (increasing the distributed capacitance of primary stage), decreasing the distance of primary stage (increasing the distributed capacitance of primary stage), and winding sparing;

 

4. Changing the circuit working parameters to reduce the AC resistance, such as reducing the switching frequency, will increase the magnetic flux density of the core and increase the iron loss. When the copper loss is significantly higher than the iron loss, use it with caution;

 

5. Use wires with lower resistivity

 

Reduce iron loss

 

1. For example, PC50 of TDK is used to replace PC40;

 

2. Reduce the flux density, but increase the number of coil turns, resulting in increased copper loss;

 

3. Change the circuit parameters, such as reducing the switching frequency, but increasing the flux density at the same time. Use it with caution, and adjust the number of winding turns when necessary;

 

4. Reasonable thermal design, using the valley value of core material temperature and loss curve;

 

Comprehensive approach

 

1. The proportion of copper loss and iron loss should be reasonably distributed according to their heat dissipation conditions;

 

2. The flux density and working frequency of the core are designed reasonably to make the core work in the best FB combination state