Today you must learn about powdered iron cores and ferrite materials for winding your own toroidal coils. Click here for basic background information on powdered iron and ferrite materials. You will need to know the formulas for calculating toroidal core inductors; click HERE for FORMULAS. The cores will be made from different materials. You will also need information on powdered iron material. Now you have all the information you need to wind toroidal coils for your electronics projects. For core material table: http://www.hills2.u-net.com/electron/induct.htm#Ferrites For core material for RF applications: http://www.amidoncorp.com/ace_iptcforrf.htm
To calculate the approximate inductance of a toroid, use the JAVA calculator found here: http://hyperphysics.phy-astr.gsu.edu/hbase/magnetic/indtor.html#c1 Courtesy of Carl R. (Rod) Nave, Georgia State University. Be sure to visit their main site loaded with JAVA calculators and other science information at: HyperPhysics http://hyperphysics.phy-astr.gsu.edu/hbase/hph.html including an offer of a CD containing of all their fine materials.
Toroid Approximate Inductance CALCULATOR - Toroid CALCULATOR
Introduction - Use of Ferromagnetic Cores
Choice of core material - choice of material is of prime importance
What size toroid core? - Design examples are given
Using the data tables
Winding hints
Line filters and chokes
Switched mode supplies
Variable coil forms
Suppression beads
Bobbin core
Balun cores
Core cross references
Downloads
RFI suggestions
Magnetic formula
Australian resellers
Price lists
Ordering information
Links
Torroid Inductance charts: http://www.electronics-tutorials.com/basics/toroidcharts_mcq.htm
http://home.sandiego.edu/~ekim/otherjunk/inductor.pdf
Impedance/Reactance http://www.kpsec.freeuk.com/imped.htm
Testing Unknown Ferrite Cores
Ferrites are roughly divided into two groups. Those with permeabilities up to 850 are usually made from nickel-zinc material and have high volume resistivity ranging from 1x105 to 1x108. Higher permeability ferrites are usually made from manganese-zinc material and have volume resistivity ranging from 0.1x102 to 1x102. Iron powder cores are usually color coded and have very high volume resistivity. An initial test of the material can be made by checking the dc resistance between opposite faces/sides of a core. Low readings indicate a high permeability material. If you can measure inductance at a low frequency (10-100kHz), wind 10 turns of wire on the core and measure the inductance. You can then work back from the ferrite material formula and calculate the AL value, which can be compared with the tables of known cores of the same physical dimensions and so come up with a reasonable match. If 10 turns does not give a measurable reading try 20 or 30 turns.
RF power rating can be roughly checked by using two exactly similar cores each wound with the same primary and secondary turns (say 10 turns each on primary and secondary) and then connecting the cores back to back as shown. This arrangement provides a 1:1 equivalent so that the transmitter sees the correct load. Losses are doubled by using two transformers, but this does not matter for the test. Set the transmitter to the desired frequency and reduce the rf power output to a minimum. Increase the power output in small steps (say 5 -10W per step) holding each setting for 30 seconds then checking the temperature of each transformer. The transformers should only get warm to touch but NEVER hot. When the final temperature of each transformer has reached about 40 deg.C you can say that you have reached the power limit for that particular core. Some cores will get hot at very low power. You have to make a value judgment about the core physical size versus the power rating achieved.
Useful hints concerning winding toroid coils.
Building a toroid http://www.hamradio-online.com/1999/apr/w6bky-10.html
Toroid Inductance Charts http://www.electronics-tutorials.com/basics/toroidcharts_mcq.htm
A GREAT Inductor Impedance CALCULATOR online - http://www.cvs1.uklinux.net/cgi-bin/calculators/ind_imp.cgi
A GREAT Tuned Circuit Impedance CALCULATOR online - http://www.cvs1.uklinux.net/cgi-bin/calculators/tuned_circuit.cgi
To calculate the approximate inductance of a toroid, use the JAVA calculator found here: http://hyperphysics.phy-astr.gsu.edu/hbase/magnetic/indtor.html#c1 Courtesy of Carl R. (Rod) Nave, Georgia State University. Be sure to visit their main site loaded with JAVA calculators and other science information at: HyperPhysics http://hyperphysics.phy-astr.gsu.edu/hbase/hph.html including an offer of a CD containing of all their fine materials.
Toroid Approximate Inductance CALCULATOR - Toroid CALCULATOR
Introduction - Use of Ferromagnetic Cores
Choice of core material - choice of material is of prime importance
What size toroid core? - Design examples are given
Using the data tables
Winding hints
Line filters and chokes
Switched mode supplies
Variable coil forms
Suppression beads
Bobbin core
Balun cores
Core cross references
Downloads
RFI suggestions
Magnetic formula
Australian resellers
Price lists
Ordering information
Links
Torroid Inductance charts: http://www.electronics-tutorials.com/basics/toroidcharts_mcq.htm
http://home.sandiego.edu/~ekim/otherjunk/inductor.pdf
Impedance/Reactance http://www.kpsec.freeuk.com/imped.htm
Testing Unknown Ferrite Cores
Ferrites are roughly divided into two groups. Those with permeabilities up to 850 are usually made from nickel-zinc material and have high volume resistivity ranging from 1x105 to 1x108. Higher permeability ferrites are usually made from manganese-zinc material and have volume resistivity ranging from 0.1x102 to 1x102. Iron powder cores are usually color coded and have very high volume resistivity. An initial test of the material can be made by checking the dc resistance between opposite faces/sides of a core. Low readings indicate a high permeability material. If you can measure inductance at a low frequency (10-100kHz), wind 10 turns of wire on the core and measure the inductance. You can then work back from the ferrite material formula and calculate the AL value, which can be compared with the tables of known cores of the same physical dimensions and so come up with a reasonable match. If 10 turns does not give a measurable reading try 20 or 30 turns.
RF power rating can be roughly checked by using two exactly similar cores each wound with the same primary and secondary turns (say 10 turns each on primary and secondary) and then connecting the cores back to back as shown. This arrangement provides a 1:1 equivalent so that the transmitter sees the correct load. Losses are doubled by using two transformers, but this does not matter for the test. Set the transmitter to the desired frequency and reduce the rf power output to a minimum. Increase the power output in small steps (say 5 -10W per step) holding each setting for 30 seconds then checking the temperature of each transformer. The transformers should only get warm to touch but NEVER hot. When the final temperature of each transformer has reached about 40 deg.C you can say that you have reached the power limit for that particular core. Some cores will get hot at very low power. You have to make a value judgment about the core physical size versus the power rating achieved.
Useful hints concerning winding toroid coils.
Building a toroid http://www.hamradio-online.com/1999/apr/w6bky-10.html
Toroid Inductance Charts http://www.electronics-tutorials.com/basics/toroidcharts_mcq.htm
A GREAT Inductor Impedance CALCULATOR online - http://www.cvs1.uklinux.net/cgi-bin/calculators/ind_imp.cgi
A GREAT Tuned Circuit Impedance CALCULATOR online - http://www.cvs1.uklinux.net/cgi-bin/calculators/tuned_circuit.cgi
6 comments:
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