TRANSFORMER AND INDUCTOR DESIGN HANDBOOK

This book offers a practical approach, with design examples for design engineers and system engineers in
the electronics and aerospace industries. Transformers are found in virtually all electronic circuits. This
book can easily be used to design lightweight, high-frequency aerospace transformers or low-frequency
commercial transformers. It is, therefore, a design manual.

The conversion process in power electronics requires the use of transformers, components that frequently
are the heaviest and bulkiest item in the conversion circuit. Transformer components also have a significant
effect on the overall performance and efficiency of the system. Accordingly, the design of such
transformers has an important influence on overall system weight, power conversion efficiency, and cost.
Because of the interdependence and interaction of these parameters, judicious trade-offs are necessary to
achieve design optimization.

Manufacturers have, for years, assigned numeric codes to their cores to indicate their power-handling
ability. This method assigns to each core a number called the area product, Ap, that is the product of its
window area, Wa, and core cross-section area, Ac. These numbers are used by core suppliers to summarize
dimensional and electrical properties in their catalogs. The product of the window area, Wa, and the core
area, Ac, gives the area Product, Ap, a dimension to the fourth power. I have developed a new equation for
the power-handling ability of the core, the core geometry, Kg. Kg has a dimension to the fifth power. This
new equation provides engineers with faster and tighter control of their design. It is a relatively new
concept, and magnetic core manufacturers are now beginning to include it in their catalogs.
Because of their significance, the area product, Ap, and the core geometry, Kg, are treated extensively in this
handbook. A great deal of other information is also presented for the convenience of the designer. Much of
the material is in tabular form to assist the designer in making the trade-offs best suited for a particular
application in a minimum amount of time.

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