In old magazine (Radio – Радио) I found small article about calculating PWM power transformers. The formulas are for toroid core transformers, but I think, they are usable in standard E core transformers too.
1. Calculate the power of transformer: Pt
=1.3*ΣPn
, W. The power of transformer is sum of all output powers multiplied by 1.3.
2. The core max power: P=Sc
*So
*f*Bmax
/150 , W. f=Hz, Sc
=area of core section in cm2
, So
=area of the “hole” in cm2
. Bmax
= max induction in Teslas, from core datasheet.
3. Number of turns in primary winding: w1
=0.25*104
*U1
/fBmax
Sc
, in turns.
4. Max current in primary winding: I1max
=P/ηU1
, A. (η = ~0.8)
5. Diameter of wire: d1
=0.6*√I1max
, mm. diameter is equal 0.6 multiplied by square root of max current.
6. Secondary (ant other) winding: w2
=w1
*U2
/U1
, in turns.