INTRODUCTION

In our generation, power supply is very important in our everyday living in the way like our life will not be complete without it. Thats why they invented the transformer for power transmission. Being an electrical engineering student, we have known everything about power transmission through the use of transformer. But will it be proper to know everything about transformer. Not just the theoretical knowledge about transformer but how to construct a generating transformer. But first we must know what a transformer is. A transformer is a device which uses the phenomenon of mutual induction to change the values of alternating voltages and currents. In fact, one of the main advantages of a.c. transmission and distribution is the ease with which an alternating voltage can be increased or decreased by transformers. Transformers range in size from the miniature units used in electronic applications to the large power transformers used in power stations. The principle of operation is the same for each. Now that we discuss what a transformer is, we will now tackle what will be the paper all about. In this paper we will be using laminated core or EI core power transformer. This is the most common type of transformer, widely used in appliances to convert mains voltage to low voltage to power electronics. This paper will discuss about power transformers which converts AC to DC supply, and step down the supply to 19-volts 5-amperes output. It will tackle how the transformers function and its application, and how to compute the specification to construct such transformer. And tells what are the needed apparatus and materials for the construction and what will be the step-bystep procedure on constructing this kind of transformer.

FUNCTION
Although the transformer is not an energy conversion device, it is an indispensable component in many energy conversion systems. As one of the principal reasons for the widespread use of ac power systems, it makes possible electric generation at the most economical generator voltage, power transfer at the most economical transmission voltage, and power utilization at the most suitable voltage for the particular utilization device. The transformer is also widely used in low-power low-current electronic and control circuits for performing such functions as matching the impedances of a source and its load for maximum power transfer, insulating one circuit from another, or isolating direct current while maintaining ac continuity between two circuits.

Transformers are needed in electronic apparatus to provide the different values of plate, filament, and bias voltage required for proper tube operation, and to maintain or modify wave shape and frequency response at different potentials. A transformer can convert AC (Alternating Current) to DC (Direct Current) supply through the use of a rectifier. Another function of the transformer is to allow AC voltage to be readily converted from one voltage level to another. This way, the power can be generated at a relatively low voltage. A transformer is used to step the voltage up to a transmission level close to the use point of the power, the voltage is stepped back down, and then routed to the transformer on the utility pole behind the house or close to the industrial plant. The final step down transformer changes the voltage to a utilization level. This kind of transformer is called the power transformer. Though, this paper will focus on the power transformer which converts AC to DC supply, and for electronic devices which uses low-power low-current supply, this function of transformer for a high-power distribution is just included for better understanding of the function of a transformer.

APPLICATION
Transformers are needed in electronic apparatus to provide the different values of plate, filament, and bias voltage required for proper tube operation, and to maintain or modify wave shape and frequency response at different potentials. A power transformer with 19-volts and 2.1-amperes output with 60 hertz operating frequency are usually applied in the charger of some electronic devices or apparatus. One of its applications is on laptop or portable computer. Most of the laptop with this output specification is Netbook, usually small in size and only use for searching and typing.. Another application is on television. Usually apply in wide screen flat televisions which most of them are using an adaptor to connect to a source. Any electronic devices or gadgets and appliances with this output specification will be suitable to use for supplying power to operate.

PROPERTIES
Occasionally someone asks why electronic transformers cannot be designed according to curves or charts showing the relation between volts, turns, wire size, and power rating. Such curves have appeared in magazines and have been used for small control transformers. The

idea is that by means of such charts any engineer can design his own transformer. However, this idea has not been found practicable for the following reason. (a) Regulation. It regulates 220 Volts to 19 Volts, 2.1 Amperes and 60 Hertz output. This property is rarely negligible in electronic circuits. It often requires care and thought to use the most advantageous winding arrangement in order to obtain the proper IX and IR voltage drops. Sometimes the size is dictated by such considerations. (b) Frequency Range. It frequency is 60 Hertz fixed. The low frequency end of a transformer operating range in a given circuit is determined by the transformer opencircuit inductance. The high frequency end is governed by the leakage inductance and distributed capacitance. Juggling the various factors, such as core size, number of turns, interleaving, and insulation, in order to obtain the optimum design constitutes a technical problem of the first magnitude. (c) Voltage. It voltage is 19 Volts. It would be exceedingly difficult, if not impossible, to reduce to chart form the use of high voltages in the restricted space of a transformer. Circuit considerations are very important here, and the transformer designer must be thoroughly familiar with the functioning of the transformer to insure reliable operation, low cost, and small dimensions. (d) Size. Its size is small, the same size with the adaptor of a netbook and notebook laptop. Much electronic equipment is cramped for space and, since transformers often constitute the largest items in the equipment, it is imperative that they, too, be small size. An open-minded attitude toward this condition and the use of good judgement may make it possible to meet the requirements which otherwise might not be fulfilled. The use of new materials, too, can be instrumental in reducing size in some instances down to a small fraction of former size. (e) Rectification. A rectifier is an electrical device use to converts alternating current (AC), which periodically reverses direction, to direct current (DC), which flows in only one direction. (f) Filter. A device that is designed to physically block certain objects or substances while letting others through. This circuit reduces ripple voltage to become smooth DC voltage. Some advantages properties of a power transformer using EI core will be enumerated below. Widely available in power ratings ranging from mW to MW Insulated lamination minimizes eddy current losses Small appliance and electronic transformers may use a split bobbin , giving a high level of insulation between the windings Rectangular core

 Core laminate stampings are usually in EI shape pairs. Other shape pairs are sometimes used Mu-metal shields can be fitted to reduce EMI (electromagnetic interference) A screen winding is occasionally used between the 2 power windings Small appliance and electronics transformers may have a thermal cut out built in Occasionally seen in low profile format for use in restricted spaces Laminated core made with silicon steel with high permeability

DEFINITION OF TERMS
Magnetic Circuit is made up of one or more closed loop paths containing a magnetic flux. Power factor is defined as the ratio of the real power flowing to the load to the apparent power in the circuit. Split bobbin is the method of winding a transformer whereby the primary and secondary are wound side by- side on a bobbin with an insulation barrier between the two wingdings. Mu-metal is a nickel-iron alloy that is notable for its high magnetic permeability. Eddy current loss is the induction of eddy currents within the core causes a resistive loss.

Electromagnetic interference (EMI) is disturbance that affects an electrical circuit due to either electromagnetic induction or electromagnetic radiation emitted from an external source. field.

Permeability is the degree of magnetization of a material in response to a magnetic EI core is a sheets of suitable iron stamped out in shapes like the letters "E" and "I",
are stacked with the "I" against the open end of the "E" to form a 3-legged structure.

Biasing is the method of establishing predetermined voltages or currents at various

points of an electronic circuit to set an appropriate operating point. Filament is a thin heating element. Alternating Current (AC) the movement of electric charge periodically reverses direction. Direct Current (DC) is the unidirectional flow of electric charge. Impedance is the complex ratio of the voltage to the current in an alternating current (AC) caircuit. RMS Value, In mathematics, the root mean square (abbreviated RMS or rms), also known as the quadratic mean, is a statistical measure of the magnitude of a varying quantity. It is especially useful when variates are positive and negative, e.g., sinusoids.

 AWG (American Wire Gauge) also known as the Brown & Sharpe wire gauge is a standardized wire gauge system used since 1857. Interpolation means to estimate a value of (a function or series) between two known values; to make insertions or additions. Transformer is a device used to transfer electric energy from one circuit to another, especially a pair of multiply wound, inductively coupled wire coils that affect such a transfer with a change in voltage, current, phase, or other electric characteristic. Voltage Regulation is the change in voltage magnitude that occurs when the load (at a specified power factor) is reduced from the rated or nominal value to zero, with no intentional manual readjustment of any voltage control, expressed in percent of nominal full-load voltage. Wiring is the material, as wire or rope, wound or coiled about anything, or a single round or turn of the material; as (Elec.), a series winding, or one in which the armature coil, the field-magnet coil, and the external circuit form a continuous conductor; a shunt winding, or one of such a character that the armature current is divided, a portion of the current being led around the field-magnet coils.

EXECUTIVE SUMMARY
Specification Needed: Primary Voltage: 220 Vrms Secondary Voltage, Current: 19 Volts dc, 2.1 Amperes Operating Frequency = 60 Hz Step 1: Compute the total voltage across the secondary: Esn = 2.35 Edc Esn = 44.65 Volts Where: Edc => Secondary Voltage in Volts 2.35 => twice the ratio of the RMS to average value plus 5% regulation Step 2: Compute the secondary currents from: Is = k Idc Is = 2.226 Amperes Where: Is => secondary current in Amperes k => k factor (see Table 1) Step 3: Compute the output power in Watts. Pout = Es Is Pout = 99.3909 Watts Where: Es => Secondary Voltage in Volts Is => Secondary current in Amperes

Step 4: Compute the required input power in Volt-Amperes. VA =

out

(n) VA = 128.4568 Volt-Amperes

Where: Pout n 0.9 VA Step 5: Assume a square core area for convenience and compute for the required area and the size of the EI lamination.

=> => => =>

Required Output Power computed previously efficiency of the transformer power factor Power input in Volt-Amperes

A=

A = 2.0312 in2 Where: A => cross section area of the core in square inches (n2). Compute for the tongue width ( tw ) and the stacking height ( g ). g = tw = g = tw = 1.4252 in Then use Table 3 to choose the size of the EI lamination required. g = tw = 1.5 in The size of the EI lamination also gives the winding length ( wl ), which should not exceed the tongue width ( tw ) and the allowable winding build-up which should not be greater than the EI laminations window The details are shown in Figure 6.

Step 6: Compute for the number of the primary and secondary turns Np and Ns.
Ep 1

Np =

f Np = 473.9506 turns 474 turns

Ns = 1.05 Np (

Ns = 101.0105 turns 102 turns Where: Np Ns Ep Es f A B Step 7: Compute for the size of the magnetic wires to be used for the coils. Ip = Ip = 0.5839 Ampere Where: Ip => current in the primary Compute for the diameter of the wires for the primary and the secondary coils.
I
1

=> => => => => => =>

number of turns in the primary number of turns in the secondary primary voltage in RMS (22CV) secondary voltage in RMS frequency of operation in Hz (60Hz) tongue area in square inches flux density in Gauss (Table 3)

d = 1.13 *

log in dp = 0.0246 inch diameter ds = 0.0479 inch diameter

Where: d => diameter of the wire in inches I => current in the wire in Amperes Pin => required power in Volt-Amperes The commercially available wire gauges based on the diameter of the wire are shown in Table 4. Primary wire size: # 22 AWG, dp = 0.0253 inches Secondary wire size: # 16 AWG, ds = 0.0508 inches Step 8: Compute for the number of turns per layer. Initially compute for the allowable winding length. wl = tl 2(margin) 2(bobbin allowance) wl = 1.936 inches Where: wl => winding length tl => tongue length margin => 0.125 inches bobbin allowance => 0.032 inches The number of turns per layer:
turns layer

wl diameter of wire with insulation

Primary: turns = 72.7820 turns/layer 73 turns/ r Secondary: turns = 36.9466 turns/ r 37 turns/ r

Step 9: Compute the winding build up of the primary and secondary winding. WBtot = 1.1 (WBp + WBs + bobbin thickness + inter winding insulation) WBtot = 0.5086 inch Where: WBtot => total winding build up WBp => winding build up in the primary WBs => winding build-up in the secondary Bobbin thickness => 0.095 Inter winding insulation => 0.002 number of winding The total winding build up should not exceed 90% of the EI laminations window If the computed value does exceed that amount, choose a larger EI lamination and repeat steps 6, 8 and 9. Step 10: Compute for the total length of wires needed for the transformer. Initially compute for the mean length of turns ( MLT ) of each winding. MLTp = 2 (tw + g + 4b) + WBp MLTp = 7.3889 inches MLTs = 2 (tw + g + 4b) + (2WBp + WBs) MLTs = 8.5306 inches Where: MLTp => mean length of turns in the primary MLTs => mean length of turns in the secondary g => stack height b => bobbin thickness => 0.095 WB => winding build up

The actual length of wires is computed from: L = MLT N Primary: Lp = 3,502.3386 inches Secondary: Ls = 870.1212 inches Where: L => length of the wire Step 11: Since magnet wires are sold by the weight rather by length, the total weight of the wires are computed using W(lbs) =
f 1

Primary: Wp = 0.5677 lbs Secondary: Ws = 0.5669 lbs Where: W => weight of the wire in lbs L => length of the wire f => conversion factor (see Table 4) Step 12: Determine the percent efficiency ( ) and voltage regulation ( r ) from: =
out 1

out (core loss) (copper loss) = 92.71%

Vr = Is[

Vr = 0.024 or 2.4%

Design
Specification Needed: Primary Voltage: 220 Vrms Secondary Voltage, Current: 19 Volts dc, 2.1 Amperes Operating Frequency = 60 Hz Step 1: Compute the total voltage across the secondary: Esn = 2.35 Edc Esn = 2.35 19V Esn = 44.65 Volts Where: Edc => Secondary Voltage in Volts 2.35 => twice the ratio of the RMS to average value plus 5% regulation Step 2: Compute the secondary currents from: Is = k Idc Table 1: Factors K and K for Single- Phase Rectifier Supplies Capacitor input K K Full-wave 0.707 1.06 Half-wave 1.4 2.2 Is = 1.06 2.1A Is = 2.226 Amperes Where: Is => secondary current in Amperes k => k factor (see Table 1)

Step 3: Compute the output power in Watts. Pout = Es Is Pout = 44.65V 2.226A Pout = 99.3909 Watts Where: Es => Secondary Voltage in Volts Is => Secondary current in Amperes Step 4: Compute the required input power in Volt-Amperes. VA =
out (n)

Table 2: Efficiencies for Various Sizes Power Supplies Output in Watts Approximate Efficiency in Percent 20 70 30 75 40 80 80 85 100 86 200 90 Note 1: The Interpolation Step 1: Find the range where the given value falls from the table. Pout = 44.838 Watts Range available: 40 80 Step 2: Use the formula:

x1 - d1 x1 - x

y1 - d y1 - y

Where: x1 is the smallest from the range of independent values d1 is the given value x is the highest in the range of independent values y1 is the dependent value of x1

d is the dependent value of the given value y is the dependent value of x

Computation:
-1 -d -

(0.969545)(-1) = (85 d ) -0.60475 85 = -d

2

= 85.969545

VA = VA =

VA = 128.4568 Volt-Amperes

Where: Pout n 0.9 VA => => => => Required Output Power computed previously efficiency of the transformer power factor Power input in Volt-Amperes

Step 5: Assume a square core area for convenience and compute for the required area and the size of the EI lamination.

A=

A=

A = 2.0312 in2 Where: A => cross section area of the core in square inches (n2).

Compute for the tongue width ( tw ) and the stacking height ( g ).

g = tw = g = tw = g = tw = 1.4252 in Then use Table 3 to choose the size of the EI lamination required.

Table 3. EI Core Data on , Tongue Lamination, and D Core Weight Core At 60 Hertz EI Type Tongue Width of Weight EI B (gauss) Lamination Lamination (inches) (lb) 3.9 14,000 EI 21 0.5 0.199 5.8 14,000 EI 625 0.625 0.361 13.0 14,000 EI 75 0.75 0.609 17.0 14,000 EI 75 0.75 0.812 24.0 13,500 EI 11 0.875 0.966 37.0 13,000 EI 12 1.00 1.43 54.0 13,000 EI 12 1.00 2.14 82.0 12,500 EI 125 1.25 2.83 110 12,000 EI 125 1.25 3.97 145 12,000 EI 13 1.5 4.92 195 11,000 EI 13 1.5 6.56 525 10,500 EI 19 1.75 9.75 Since 1.5 is the closest value to 1.4252, choose EI-13. g = tw = 1.5 inches The size of the EI lamination also gives the winding length ( wl ), which should not exceed the tongue width ( tw ) and the allowable winding build-up which should not be greater than the EI laminations window

W = tw
1

W = (1.5) W = 0.75 inch tl = tw

tl = (1.5) tl = 2.25 inches

Step 6: Compute for the number of the primary and secondary turns Np and Ns.
Ep 1 f ( )1

Np =

Np =

(1 ) (1 ) Np = 473.9506 turns 474 turns

Ns = 1.05 Np ( Ns = 1.05 (474) (

Ns = 101.0105 turns 102 turns Where: Np Ns Ep Es f A B Step 7: Compute for the size of the magnetic wires to be used for the coils. Ip =
1

=> => => => => => =>

number of turns in the primary number of turns in the secondary primary voltage in RMS (22CV) secondary voltage in RMS frequency of operation in Hz (60Hz) tongue area in square inches flux density in Gauss (Table 3)

Ip =

Ip = 0.5839 Ampere

Where: Ip => current in the primary Compute for the diameter of the wires for the primary and the secondary coils.
I log in
1

d = 1.13 *

+
1

dp = 1.13 *

log 1 dp = 0.0246 inch diameter

ds = 1.13 *

log 1 ds = 0.0479 inch diameter

Where: d => diameter of the wire in inches I => current in the wire in Amperes Pin => required power in Volt-Amperes The commercially available wire gauges based on the diameter of the wire are shown in Table 4.

Table 4: Magnet wire data on diameter, resistance, and Core Weight. AWG Diameter in inches Ohms per Pounds per Margin m B&S 1000 Ft. in inches Bare Enamelled 1000 Ft. Gauge 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 0.1019 0.0927 0.808 0.0719 0.0641 0.0571 0.0508 0.0453 0.0403 0.0359 0.0320 0.0285 0.0253 0.0403 0.0359 0.0179 0.0159 0.0142 0.0126 0.0113 0.0100 0.0089 0.0080 0.0071 0.0063 0.0056 0.0050 0.0045 0.0040 0.0035 0.0031 0.1039 0.0927 0.0827 0.0738 0.0659 0.0588 0.0524 0.0469 0.0418 0.0374 0.0334 0.0299 0.0266 0.0239 0.213 0.0190 0.0169 0.0152 0.0135 0.0122 0.0109 0.0097 0.0088 0.0079 0.0070 0.0062 0.0056 0.0050 0.0045 0.0040 0.0036 0.9989 1.260 1.588 2.003 2.525 3.184 4.016 5.064 6.385 8.051 10.15 12.80 16.14 20.36 25.67 32.37 40.81 51.47 64.90 81.83 103.2 130.1 164.1 206.9 260.9 329.0 414.8 523.1 659.6 831.8 1049 31.43 24.92 19.77 15.68 12.43 9.858 7.818 6.200 4.917 3.899 3.092 2.452 1.945 1.542 1.223 0.9699 0.7692 0.6100 0.4837 0.3836 0.3042 0.2413 0.1913 0.1517 0.1203 0.0954 0.0757 0.0600 0.0476 0.0377 0.0299 0.25 0.25 0.25 0.25 0.25 0.25 0.1875 0.1875 0.1875 0.1562 0.1562 0.1562 0.125 0.125 0.125 0.125 0.125 0.125 0.125 0.125 0.125 0.125 0.0937 0.0937 0.0937 0.0937 0.0937 0.0937 0.0625 0.0625 0.0625

Primary wire size: # 22 AWG, dp = 0.0253 inches Secondary wire size: # 16 AWG, ds = 0.0508 inches Step 8: Compute for the number of turns per layer. Initially compute for the allowable winding length. wl = tl 2(margin) 2(bobbin allowance)

wl = 2.25 2 (0.125) 2 (0.032) wl = 1.936 inches Where: wl => winding length tl => tongue length margin => 0.125 inches bobbin allowance => 0.032 inches

The number of turns per layer:

turns layer

wl diameter of wire with insulation

No. of Layers = turns

layer

Primary:
turns layer turns r

= = 72.7820 turns/ r 73 turns/ r

No. of Layers = No. of L Secondary:

turns layer turns r

rs = 6.4932 7

rs

= = 36.9466 turns/
1

r 37 turns/

No. of Layers = No. of L

rs = 2.7568 3

rs

Because some figures were rounded off, check if the values still satisfy the number of turns in the primary winding. Checking:
turns layer

p o of ayers

turns No. of Turns = (layer)(No. of Layers)

For Primary:
turns layer turns r

= = 67.714 turns/ r 68 turns/ r

No. of Turns = (68)(7) No. of Turns = 476 turns For Secondary:

turns layer turns r

= 34 turns/layer

No. of turns = (34)(3) No. of turns = 102 turns Step 9: Compute the winding build up of the primary and secondary winding. p = o of layers in primary (dp insulation) inter layer

WBp = 7 (0.0266 + 0.002) WBp = o.2002 inch s = o of layers in secondary (dsn insulation) WBs = 3 (0.0524 + 0.002) WBs = 0.1632 inch

inter layer

WBtot = 1.1 (WBp + WBs + bobbin thickness + inter winding insulation) WBtot = 1.1 (0.095 + 0.2002 + 0.1632 + 2 (0.002)) WBtot = 0.5086 inch Where: WBtot => total winding build up WBp => winding build up in the primary WBs => winding build-up in the secondary Bobbin thickness => 0.095 Inter winding insulation => 0.002 number of winding

The total winding build up should not exceed 90% of the EI laminations window If the computed value does exceed that amount, choose a larger EI lamination and repeat steps 6, 8 and 9.

Step 10: Compute for the total length of wires needed for the transformer. Initially compute for the mean length of turns ( MLT ) of each winding. M Tp = (tw g b) WBp )) ( )

M Tp = (1 1 ( MLTp = 7.3889 inches

MLTs = 2 (tw + g + 4b) + (2WBp + WBs) M Ts = (1 1 ( MLTs = 8.5306 inches )) ( ( ) 1 )

Where: MLTp => mean length of turns in the primary MLTs => mean length of turns in the secondary g => stack height b => bobbin thickness => 0.095 WB => winding build up

The actual length of wires is computed from: L = MLT N Primary: Lp = 7.3889 474 Lp = 3,502.3386 inches Secondary: Ls = 8.5306 102 Ls = 870.1212 inches Where: L => length of the wire Step 11: Since magnet wires are sold by the weight rather by length, the total weight of the wires are computed using W(lbs) = Primary: Wp =
1 1

f 1

1 Wp = 0.5677 lbs

Secondary: Ws =
1 1

1 1 Ws = 0.5669 lbs

Where: W => weight of the wire in lbs L => length of the wire f => conversion factor (see Table 4)

a. Winding resistances (From Table 4) Rp =

p 1

1 1 1

Rp =

1 Rp = 4.7106 s 1 1 1

1 1 1

Rs =

Rs =

1 1

1 Rs = 0.2912

1 1

Where: Rp => winding resistance in the primary Rs => winding resistance in the secondary b. Copper losses Cp = Ip2 Rp Cp = (0.5839)2 (4.7106) Cp = 1.606 Watts Cs = Is2 Rs Cs = (2.1)2 (0.2912) Cs = 1.2842 Watt Ctot = Cp + Cs Ctot = 1.606 + 1.2842 Ctot = 2.8902 Watts

Where: Cp => copper loss in the primary Cs => copper loss in the secondary Ctot => total copper loss c. Core loss (From Table 5 and Table 3) Core loss = (Approx. Core loss) (Core Weight) Table 5: Core characteristics data at different operating frequencies. Freq. Lamination Core Flux Approximate Core in Thickness Density Core Loss Material Hertz (inches) Bm in Gauss in Watts/Lb 25 60 60 400 800 0.025 0.014 0.014 0.004 0.004 2.5% silicon 4% silicon Grain-oriented silicon Grain-oriented silicon Grain-oriented silicon 14,000 12,000 15,000 10,000 6,000 0.65 1.0 1.0 4.5 4.5

Core loss =

(4.92 lb) 1 lb Core loss = 4.92 Watts Where: Core loss is in

att lb Core weight is in lb

att

d. Voltage Drop VDp = Ip Rp VDp = (0.5839) (4.7106) VDp = 2.7505 Volts VDs = Is Rs VDs = (2.1) (0.2912) VDs = 0.6115 Volts

Where: VDp => voltage drop in the primary VDs => voltage drop in the secondary Step 12: Determine the percent efficiency ( ) and voltage regulation ( r ) from: =
out 1 out (core loss) (copper loss) 1 ) (

= = 92.71%
*

Vr = Is[

Vr = (2.1) [ Vr = 0.024 or 2.4%

+ (

Summary of Design Computations. DC Voltage at Winding Ampere rated current Primary 220 V 0.58 A Secondary 19 V dc 2.1 A EI lamination to be used is EI-13 Number of Turns 474 102 AWG# 22 16 Weight Needed

The Output Transformer

CONSTRUCTION PROCEDURE
Step 1: Prepare the winding forms or bobbins for the winding of the coils. Make sure that the size of the bobbin will fit the tongue dimensions of the EI laminations. You will also need something to maintain the bobbin shape while you are making the windings. You see, the usual bobbin is made of cardboard material only and its form will collapse when you make the windings tight. To prevent this, make a piece of wood which will fit the bobbin. Bore a hole through the piece of wood so that it will be held securely by the winder. Step 2: Secure the strips with insulating paper, such as fish paper, which should be placed in between each windings as an inter-winding insulation. Step 3: For the layers in the same windings, the inter-layer insulation is not necessary as the wire used is already insulated. Make sure you are using magnetic wires. Step 4: Start winding the coil with the most number of turns, followed by the next highest number. This means that the primary coil would be the innermost winding, followed by the secondary designed for 19-volts dc. Do not forget to make the winding terminations accessible by connecting hook-up wires with appropriate colors to identify the windings and making them extend from the windings. Step 5: Make two piles of the laminations alternately stacking the EI laminations to the required stacking height. Place the finished coil into the tongue or center limb of one of the stacks then gently interleave the two prepared stacks. Hold the core together by clamping the laminations together by means of bolts and buts in the slots provided.

Step 6: Immerse the core and the windings in a can of varnish for 10 to 15 minutes. This is an insulation also. Remove and let the transformer dry Step 7: To complete everything, bake the transformer in the cover for about four hours or let it dry for a couple of days to let the varnish dry and remove its sticky nature. Step 8: Now your transformer is ready for testing.