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- Early in the product design cycle, talk to experienced Magnetics design engineers to discuss efficiency/cost trade-offs that can be made in specific situations.
- Determine in advance which electrical standards your products and/or its magnetic materials must meet, i.e. AS/NZ, UL, IEC, CCC or any industry-specific standards or requirements that you may be subject to, such as the "Ben'an" design for mining applications.
- Determine what other technical characteristics are required for transformers in the circuit, namely inductors, winding capacitors, efficiency, DC resistance, EMI rating, etc.
- Define any environmental or physical conditions that a transformer/product must meet, such as temperature range, humidity level, vibration resistance, etc.
- Choose a standard spool and core kit that meets your power requirements and meets both temperature rise targets.
- Balance the high cost of the patching equipment with the productivity of the placement equipment. The "ThroughHole" component is usually cheaper than the SMD, but the labor intensity on the PCB is greater.
- In general, it is good to use multi-segment spools for high-voltage transformers. This helps to meet the desired climbing distance and electrical clearance.
- If you don't have a problem with temperature increases in your product design, you can "push" the transformer by selecting a smaller spool/iron core to reduce costs.
- However, smaller cables are not necessarily cheap because windings are thinner and more expensive, and small transformers often require thinner wires and are difficult to assemble.
- For high-frequency transformers, the level of ferrite material required depends largely on the switching frequency selected.
- Grain orientation (GO) steel is at least 200% more expensive than standard H14 electrical steel, but the power is increased by up to 30%. In general, it is cheaper to get larger to gain more power unless there are large physical size limits.
- If it is not an EMI issue, consider using a higher frequency to reduce the size of the transformer.
- If there is an EMI problem, strike a balance between the required EMI suppression choke cost and the frequency and size of the transformer.
- Shielding is expensive, and the smaller the transformer, the greater the cost impact of increasing it.
- When injected with epoxy, the ferrite core is prone to cracking, resulting in a gap that may or may not fit your circuit. In general, the inductor value of the iron core decreases significantly.
- The price of the Mu metal core is 4-5 times that of H14 electrical steel and cannot be justified with a near-ratio performance. Apply only to very specific results that are not available using other materials or methods.
- If efficiency is critical, consider the "skin-concentration effect" when selecting the line diameter. Use twisted pair or Leeds lines to increase efficiency.
- Use Litz wire with caution and only if it is reasonable to give you specific results that are not available using other alternative methods, as this is very expensive. Try using a twisted pair before you go to TheRitz.
- When effective insulation between windings is required, consider using a three-layer insulation wire instead of a standard paint coating line.
- If coupling is critical, consider the Shunt Winding option.
- Always test the magnetic design in the circuit to ensure that all key parameters are met. Never think it would be very expensive.
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