Re: [TCML] Inductor design program?

[DC Cox <resonance@xxxxxxxxxxxx>]

You also need to remember that the variac used to control voltage also has
some limiting effect on the current.  Since you do not know the exact type
steel in your variac core and the type steel in your pole xmfr, it's usually
better to do the experiment I have previously described.

Dr. Resonance




On Wed, Apr 21, 2010 at 8:27 PM, bunnikillr <bunnikillr@xxxxxxx> wrote:

> 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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>
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