Choosing copper wire thickness

[whatty]

Hi,

I had designed a fly-back transformer now i need to wind it on winding i need to choose the wire gauge thickness. Can any one help me to choose the correct gauge or direct me.

i will provide data some necessary data

operating frequency : 65KHz
iP peak :1.08 A
iS peak: 9.23 A

Ip rms : 0.423 A
iS rms : 3.84 A

Core : ee 25/13/7
Np : 71 turns
NS : 8 turns
Nd : 10 turns

[jonpaul]

What is the Vp-s eg mains?

What insulation required?

EMI/safety compliance?

Use wire tables, and Magnetics Designer if you have it.

See websites of litz mfg like MWS and Rubidoux for HF /skin/prox effect tables and charts..


Jon

[Kokoriantz]

Use the AWG table.
The primary is wire No 25. The secondary must be Litz wire or multiple No 25.

[jonpaul]

The wire tables are not specific (usually!) for HF use/skin effect nor transformers with Trise, hotspots.

see excellent app notes and tables from MWS, Belden wire, etc.

Jon

[Kokoriantz]

It is specific with skin effect. No25 is suitable up to 85khz, says the table. For the secondary....?

[whatty]

Hi do i need to choose wire thickness and number of wires needed in parallel based on rms current rating or peak current rating.

Yes gauge 25 is rated for 85KHz thus it can be used for the primary my concern is when it comes to wire thickness do i need to consider rms current or peak current please tell me apart from the skin effect.

[jonpaul]

https://mwswire.com/litz-wire-tool/

https://mwswire.com

https://www.rubadue.com/

https://www.rubadue.com/our-wires/litz-wires/