Re: [TCML] Inductor design program?

[jhowson4@xxxxxxxxxxx]

I am confused. 
You are basing your turns and thus your inductance off your initial voltage or turns / volt, etc. then you decide a wire gauge based on what current you want. When do you make the connection between inductance and voltage as to actually know what the current will be vrs. what you want it do be? 

Thanks, 
John "Jay" Howson IV 

----- Original Message ----- 
From: "bunnikillr" <bunnikillr@xxxxxxx> 
To: "Tesla Coil Mailing List" <tesla@xxxxxxxxxx> 
Sent: Wednesday, April 21, 2010 11:27:02 PM GMT -05:00 US/Canada Eastern 
Subject: Re: [TCML] Inductor design program? 

Hey John... 

some basic rules of thumb on desiging your own inductor are as follows... 

determine the amount of amperage you wish to use at a maximum limit 
choose wire size based on maximum current draw 

metal core EI units with the center leg square inch area runs about 
2.5-3 amps per square inch before saturation becomes an issue 

generally, the number of winds on the EI core is about 1 wind per volt 
to be applied to the inductor 

for example: I want an inductor to handle 60 amps and will run 240 
volts thru it 

center leg size would be around 20 square inches 
Wire size would be a # 6 THHN solid copper 
and it would have about 200 winds on the center leg 

this will result in a sturdy, well built inductor and should have no 
issues handling the expected load. 


Scot D 



jhowson4@xxxxxxxxxxx wrote: 

>Hello 
>I am attempting to figure out how to design the Inductor for the ballast I am working on. does any one know of a program (free) that will allow to me to input the core dimensions, wire gauge, insulation thickness, number of turns etc. And tell me things like the inductance, resistance, will it fit in the core window, ect. 
> 
>I have been looking for about an hour now to no avail. 
>I am trying to design the Ballast I am working on but cant really find the much info about how to do it, any suggestions. 
> 
>I was planning on winding a coil and tapping it at various points, this would allow me to have a wider variety of inductance choices and thus current choices. such a plan will probably consists of multiple coils of different gauge in series. It does not make sense to wind an entire coil with 40amp wire when only 1/4 of it would only ever be carrying 40 amps. Right? 
> 
>Thanks, 
>John "Jay" Howson IV 
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