Method of winding toroidal power transformers. Encyclopedia of radio electronics and electrical engineering
Encyclopedia of radio electronics and electrical engineering / Power supply
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Among radio amateurs, toroidal transformers are very popular, as they are the least overall and massive. But each radio amateur gives a lot of trouble winding them. Someone uses shuttles for this, someone gives the cores for winding to specialists, but I get by with a simple device in the form of a wheel rim from a bicycle.
The method is simple and does not require large expenses, but it allows you to wind a power transformer for a "good" amplifier in a couple of evenings without any problems. First, prepare the toroidal core for winding. To do this, it is wrapped with one or two layers of keeper tape and varnished or, in extreme cases, with Moment glue, dried. In the same way, you need to make insulation between the windings. Instead of a keeper tape, you can use fluoroplastic tape or, in extreme cases, tape on a fabric basis. PVC electrical tape should not be used, as it melts easily even at low temperatures.
The basis of the device is an ordinary rim from a bicycle wheel. The rim is cut across and threaded into a toroidal core prepared for winding. After that, the cut part of the rim is neatly connected with a strip of metal and two screws. To support the rim, a metal pin is driven into the wall :-) so that the rim passes exactly in the middle of the toroidal core.
The device is ready and you can calculate the amount of wire needed to wind the winding. Estimate the perimeter of one turn of the primary winding. To do this, you can use a piece of wire that wraps around the core and then measure its length. Multiply the resulting length by the number of turns of the primary winding and by the "reserve" factor of 1,1 - 1,3. You will get the length of wire needed to wind the primary winding. Divide this length by the perimeter of the wheel rim and you get the number of turns of wire that need to be wound around the rim.
Now you can wind the wire around the rim. After winding, it is useful to fix the wire on the rim using a cut rubber ring (you can use a carpal rubber expander).
Now, by rotating the rim, you can wind the winding on the toroidal core. After each turn, move the rubber ring along the rim and then the wire will not get tangled. After winding the primary winding, remove the remaining wire from the rim, calculate the amount of wire to wind the next winding and continue boldly. Do not forget to put insulating tubes on the ends of the primary winding before making interwinding insulation. After winding all the windings, wrap the transformer with keeper tape and varnish it in several layers.
Author: N.Filenko (UA9XBI); Publication: cxem.net
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