Switching power supply transformers will generate heat if they are used for a long time. So, what causes this phenomenon? In fact, the reason is very simple, because the switching power supply transformer is a power transformer with a switch tube. In addition to the voltage conversion function of the ordinary transformer, the circuit also has the functions of insulation isolation and power transmission. It is generally used in switching power supplies and other high-frequency circuits. occasion.
Semiconductors, power diodes, etc. are components that are very easy to generate heat during use, and switching power supplies are no exception. The main heating components of switching power supplies are semiconductor switching tubes, power diodes, high-frequency transformers, and filter inductors. Different devices have different methods of controlling heat generation. The power tube is one of the devices that generate a large amount of heat in the high-frequency switching power supply. Reducing its heat can not only improve the reliability of the power tube, but also improve the reliability of the switching power supply and increase the mean time between failures.
Switching power supply transformer overheating solution1. For the rectification of the secondary side of the transformer, a more efficient synchronous rectification technology can be selected to reduce the loss.
2. To reduce the on-state loss, the on-state loss can be reduced by selecting a switch tube with low on-state resistance.
3. The switching process loss is caused by the gate charge and the switching time. To reduce the switching process loss, you can choose a device with a faster switching speed and a shorter recovery time.
4. For the loss caused by high-frequency magnetic materials, the skin effect should be avoided as much as possible, and the skin effect can be solved by winding multiple fine enameled wires.
5. It is important to reduce losses by designing better control methods and buffering technologies. For example, using soft switching technology can greatly reduce this loss.
6. Reduce the heat of the power diode. For AC rectifier and snubber diodes, under normal circumstances, there will be no better control technology to reduce losses. You can reduce losses by choosing high-quality diodes.
7. Try to use thick wire to wind the secondary. Try to use thick wire to rewind according to the original number of turns
8. Change to a core transformer with a larger cross-sectional area. Recalculate and debug. In addition, the secondary half-wave rectification can be changed to full-bridge rectification to reduce the DC component in the transformer and also reduce the heat generation. Also, a fan can be forced to dissipate heat.
a, try to use thick wire to wind the secondary. b, replace with a larger cross-sectional area core transformer. Among them, a is relatively simple, as long as the window allows, try to rewind the original number of turns with thick wires, and b needs to be recalculated and debugged. For those who are not proficient in switching power supplies, it may be messed up. In addition, the secondary half-wave rectification can be changed to full-bridge rectification to reduce the DC component in the transformer and also reduce the heat generation. Also, add a fan to force the heat to be able to try it.
Switching power supply transformer power reduction solution1. Choose a lower current density;
2. Reduce the number of turns, but it will increase the magnetic flux density of the core and increase the iron loss. Use it when the copper loss is significantly higher than the iron loss. Use it with caution;
3. Change the transformer process to reduce the AC resistance of the winding. The main methods are to reduce the diameter of the copper wire (cannot reduce the total cross-sectional area), increase the adjacent surface of the primary and secondary (will increase the primary and secondary distributed capacitance), reduce the distance between the primary and secondary (which will increase the primary and secondary distributed capacitance), coil sparseness, etc. ;
4. Change the working parameters of the circuit to reduce the AC resistance, such as reducing the switching frequency, but it will increase the magnetic flux density of the magnetic core and increase the iron loss. Use it when the copper loss is significantly higher than the iron loss; use it with caution;
5. Use wires with lower resistivity (not realistic). Reduce iron loss
6. Switch to core materials with better power consumption parameters, such as using TDK's PC50 material instead of PC40 material;
7. Reduce the magnetic flux density, but it will increase the number of turns of the coil and cause the copper loss to increase, so use it with caution;
8. Change the circuit parameters, such as reducing the switching frequency, but it will increase the magnetic flux density at the same time. Use it with caution and adjust the number of winding turns if necessary;
9. Reasonable thermal design, using the valley value in the core material temperature and loss curve; comprehensive method
10. According to the respective heat dissipation conditions, reasonably allocate the copper loss and iron loss ratio;
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