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Original question:

PMP8740

T4 PQ50/50 145500 transformer details

a anbarasan
Intellectual 560 points
Other Parts Discussed in Thread: UCC28950, LM5170EVM-BIDIR

Hello,

Need Transformer details (winding + core details) of transformer PQ50/50 145500  in 2kW power supply design using UCC28950.

I understand that it has been custom made. Please try to share its details (winding + core details), which will be good starting point for us.

Regards,

Anbarasan R

  • 0
    Intellectual 560 points

    Hello,

    It will be good if you can also share us with T7 and L3.  Please share the complete data sheet with the winding details, so that it can be made from our side.

    Kindly do the needfull

  • 0 in reply to a anbarasan
    TI__Guru* 86266 points

    Hello,

    Is this the design you are referring too?

    Regards,

  • 0 in reply to Mike O'
    Intellectual 560 points

    Hi mike,

    Sorry from my side for posting the same query twice.

    Yes, the same design you attached. Am summarizing my understanding on the transformer design (T1 in the document) . 

    Bobbin

    PQ 50/50

    Core

    N95

    Turns ratio

    19/2=9.5

    Primary turns (Np1)

    19 turns

    1.6 mm diameter with silk wrapping (0.1 by 120 strands)

    Cross section area=0.96133 mm2

    Current=7.5 A

    Secondary turns (Ns1)

    2 turns

    6mm diameter with silk wrapping (0.1 by app 1013 strands)

    Current=app 45 A

    Secondary turns (Ns1)

    2 turns

    6mm diameter with silk wrapping (0.1 by app 1013 strands)

    Cross section area=7.95 mm2

    Current=app 45 A

    Lm (magnetizing inductance)

    >3mH

    Please go through it for suggestions, so that we can custom design from our side.

    Also please suggest on the type of Insulation between layers (primary (Np) and secondary (ns1)/secondary (ns2)), and the operating temperature

    We also need to increase the output voltage for the same power rating. Please also suggest on this.

    Regards,

    Anbarasan R

  • 0 in reply to Mike O'
    Intellectual 560 points

    Awaiting your response....

  • 0 in reply to a anbarasan
    Intellectual 560 points

    Hi mike,

    Please try to share the complete data sheet of the Transformer T4 from Kaschke components. We are stuck at this stage

  • 0 in reply to a anbarasan
    TI__Guru* 86266 points

    Hello,

    I will contact the design of that 2 kW power supply to get the data sheet for you.

    Regards,

  • 0 in reply to Mike O'
    TI__Guru* 86266 points

    Hello,

    I have attached all the magnetic data sheets used in this reference design for your reference.

    SLUP348 Magnetic Data Sheets.zip

    Regards,

  • 0 in reply to Mike O'
    Intellectual 560 points

    Hi,

    Thanks for your data sheets....

    To add , the major problem, is we need the winding (thickness of litz wire, current density used,  insulation used between layers and turns) details of 14500-a-transformer.

    Kaschke ,  states that the design is owned by TI, and hence they are not coming forward to make one.

    Please try to give a non-objection consent on behalf of TI to Kaschke for using the design/ May be I can put one of you in loop while mailing Kaschke. Or else, Kaschke will not have problems in sharing the winding details with TI. In such a case, TI can made it open source.

    We are current working on current sharing between the 2kW power supply module and the Bidirectional Converter Evaluation Module .

    For the same, we already procured  2 Bidirectional Converter Evaluation Module (LM5170EVM-BIDIR), and we are in the process of testing the 2kW board board. We are struck in the Transformer mentioned above.

    Please try to sort out this issue.

  • 0 in reply to a anbarasan
    TI__Guru* 86266 points

    Hello,

    That does not sound correct.  TI is semiconductor manufacture and not a manufacture of magnetics.  When we design power supplies at TI we generally do not design are own magnetics for reference designs.  We give the turns ratio, RMS currents to a magnetic manufacture  like Renco and Wurth semiconductor.

    It seems like Kaschke might want you to buy the magnetic from them.

    There is a Webench design tool that I believe will give you a paper design of a transformer for  you.  You can find the Webench tool at the following link.

    Your other option is to use the excel design and give the turns ratio and RMS current requirements to a magnetic manufacture and have them design a custom transformer for you.

    Regards, 

  • 0 in reply to Mike O'
    Intellectual 560 points

    Hi,

    Sorry to be more straight forward.

    We have already given the spec. of turns ratio, rms current, core to be used, Lm value to Kaschke componenets. It has been  quite a long time, we haven't received any response from them. We are also willing to get the magnetics from Kaschke. Its all about their support and time.

    We are also not manufacturers and experts in magnetics. We are working with an M.N.C company doing escalators. We are in  a situation to move forward on the project. Hence, we thought we will use the support of TI, to work on the Transformer alone.  Hence, we thought  TI can share more information the Transformer.

    Anyways, let me try with worth and renco.

    Please try to communicate with Kaschke to help us on the issue.

    Regards,

    Anbarasan R

  • 0 in reply to a anbarasan
    TI__Guru* 86266 points

    Hello,

    Thanks for feedback and I have worked with Renco before in the past and they are top notch at designing magnetics.

    Regards,

  • 0 in reply to Mike O'
    Intellectual 560 points

    Hi Mike,

    Thanks for your suggestions. I have contacted Renco and Worth for transformer. They have replied positively. 

    Apart from this, I have few queries/suggestions needed on the 2-kW industrial AC/DC battery charger reference design with 92% full-load efficiency-PMP8740.

    We have planned to increase the voltage rating of the existing 2kW PCB board (2-kW industrial AC/DC battery charger reference design with 92% full-load efficiency-PMP8740) from 32 to 48V, keeping the power same. Am summarizing the changes necessary, from my perspective

    • Fly back transformer has to be modified
    • Output filter capacitors voltage rating has to be changed.
    • Voltage rating of the secondary side MOSFTETs(synchronous rectifier) has to be increased.

    Please advice, for any other changes/modifications needed.

     Also, we planned for few modifications on the existing desig (keeping the control same-Peak current control -PCM) please also suggest on the same.

    1. Compromising on efficiency, can we change the output MOSFETs (Synchronous rectifiers) to diode of appropriate rating?
    2. In such a case (referring 1st point), can we run the board at CCM mode under all load conditions by 1. Disabling the Burst mode (providing it with minimum Tmin) and 2. connecting the DCM pin to ground ( disabling the DCM mode).
    3. Can be set a fixed delay for all load conditions-by resistor RAB and connecting the ADEL pin to ground. Apart from reduction in efficiency, will there be any malfunction observed?
    4. In UCC28950 600-W, Phase-Shifted, Full-Bridge Application Report, fixed delay has been used to achieve ZVS from 100% to 50% load, and below 50% the converter will be operating in Valley Switching. How will the controller recognize the light load condition when the ADEL and ADELEF pins are not connected to the CS pin.

     

    Please revert back.

    Regards,

    Anbarasan R

  • 0 in reply to a anbarasan
    TI__Guru* 86266 points

    Hello,

    I have worked with Renco before and they should be able to help you get your transformer designed.

    Regards,

  • 0 in reply to a anbarasan
    TI__Guru* 86266 points

    Hello,

    I have worked with Renco in the past and I believe they should be able to help you with your transformer design.

    Regards,