12V 50A 600W power supply - (re)winding the transformer
ฝัง
- เผยแพร่เมื่อ 12 ก.พ. 2021
- Today, let's rewind the faulty transformer of my 12V 50A 600W switching power supply. I wound it partially the original way (with some original shortcomings), just using copper instead of aluminium, and splitting the secondary into more parallel wires, leaving the original design of the primary. Of course it could be redesigned much better, fitting higher cross section of copper into it to reduce the current density. It could also use many more of thinner wires to further reduce the skin effect. The returns that waste space could be eliminated by winding each section in two layers. The secondary could be a copper strip which is more space-efficient for high current low voltage windings.
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Previous episode - failure analysis & transformer autopsy:
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First episode - the teardown of this power supply:
• 12V 50A 600W power sup...
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It was fascinating to see you working on that transformer. Very good job fitting all those turns in there!
I think I could have fitted 50% more copper into it :). But it's always tricky and you never know if it fits or if it hits the ferrite core :D. The layers always take more space than on paper.
@@DiodeGoneWild i do agree with you.
@@raffaellobottoni871*me too*
I am still wanting to know how many amps is that mains fuse that didn't blow up when the PSU got shorted and tripped the 16A breaker. Can you check it?
Highly underrated comment. I hope he will read it. He could test it quick in the intro of the next video...
Something like 10A probably, fuses in power electronics are usually the last thing to blow though :P
And, with dead short circuits like that, the circuit breaker operates significantly faster than a regular fuse, not giving it time to melt.
@@iaaqob8318 Ya but still curious whether fuse is genuine or whether the uncle from the back street behind Shenzhen market sold you fake ones.
@@iaaqob8318 yes , right it only blows whenever Rectifier gets internally shorted
@@iaaqob8318 i was about to same the same thing. you said it perfect. in England and here in Ireland we normally have 13A fuse's, but this been a China job its hard to know they have put in there!
This Transformer became a piece of ART!
The transformer in the thumbnail
*E H Ǝ*
@@agustinusreynaldi7101 🤜👊🤛
Yeah definitely
Yours is the best electronics channel on TH-cam for me.
I’m addicted to your videos, partly to see when you say ‘dodgy’, and ‘bloody hell’ in your melodious tones!
Learnt more about transformers in this one video than i have watching all other electronic videos for the past 10 years.. big Clive and eev blog must have been letting me down... Lol... Thanks for another informative video.. you rock dude.. 🤘
Dr Donkey is the best 👌
This channel is seriously the best practical knowledge channel I've found on TH-cam. Taking the dark arts like switching power supply failure analysis and actually making it understandable to those with some background. Not to mention the presentation is so entertaining and engaging! Thank you so much for your work, it's appreciated greatly :)
I was sure it was going to end up too fat to fit back into the same core, which is what happens to me... it's probably cos I don't have a cat to supervise my work.
im so glad that you re-wound it. that was so cool.
This is simply unsurpassed professionalism!
Fantastic video! We've seen lots of dodgy coils. It's great to see how it should be done properly and to understand the difference.
Very pleasing to see you rewind the transformer instead of just scrapping the power supply.
I have never seen anyone, who does videos on TH-cam about electronics, explain in such detail every step like you do. Thank you for your videos. Your knowledge is astounding! Cheers from the USA!
DGW: This transformer is super dogy !
Viewers: Them do it better !
DGW: Do it better.
Viewers: Aren't surprised but are happy.
Agree , can you do it better please ?
We all already know this is the best channel on youtube. But just incase, he made this......... pure GOLD.
I'm a noob when it comes to electronics, always enjoy watching your videos. Keep them coming. Thx for educating me!
Thank you for doing the winding with a lot of useful notes regarding .
Really great that you took the time to do this for everyone who commented. A super non-dodgy job! Well done.
why I like this channel 1. Cats 2.Funny accent 3.Your freaking genius
You're the best I have seen on TH-cam. Congrats, keep it coming.
Best vid I've seen regarding how transformers work
Thanks for the awesome and informative transformer rewind! This is currently one of the best electronics channels on youtube and that's coming from someone who watches a lot of them. You obviously know a lot about this stuff and I like your unique presentation and editing style; even the drawings are great.
That's some really satisfying work! Thanks for responding the comments and making this video!
Excellent video, I love your work and the manner you present it each time, thank you !!!
I’m a woodworker but I am learning tons about electronics it will come in very handy in the future thank you very much.
incredible - i learned so much - thank you for acceding to our request.
Great tutorial on transformer windings. Thank you.
That's done properly, as it should have been to start with. Nice job!
Great job. You are a great engineer.
Great vid, thank you.
Many years ago I re-wound a transformer. It had 18kg of copper.
Good work Dan. Thanks for the video.
i will be a patron for doing this. love you!
This is my best electronic tutoring channel. You're doing a great job keep it up!
By the way, am really looking forward to the working principle of the oscillator and schematics thank you.
Really useful info showed in the rewinding process of this transformer!
You have just improved that switchmode :-D
Less loss in the wire.
Any slight difference in the turns will be cancelled by the opto feedback voltage correction.
Love your voice....bro...the way you speaking....i loved it and....Enjoying every video of you...nice and unique information every time...and I m from india...
parabéns amigo! você é o unico que teve sabedoria e esforço de nos presentear com sua inteligencia aplicada nas fontes chaveadas ou seja power supply switing
The end tape is called "margin tape", they sell it on ebay/aliexpress.
By the way, can you do a video on calculating the number of turns for a transformer?
I, also, request calculating number of turns.
@@peckelhaze6934 - Ratio. For example, 10 turns primary and 20 turns secondary = 1:2 so that would step up the voltage by a factor of 2.
Yes No. of turns calculations please.
Good idea, a short tutorial for designing own transformers.
If interested in that though, I recommend reading the "Power Supply Cookbook", all important information contained therein.
Yes, please a video how to calculate the number of turns for primary and secondary for a given transformer core. BTW: I love his videos!!!!!
Very Great efforts Sir. I really Appreciate your Efforts.
Can't wait to see the next video on this.
very happy to you fix that one! : ) and as always knowledge been shared... THANK YOU!! D..
Subscribed. Love your explanations and your accent. Very good stuff. Thank you!
Your explanation of the most fundamental construction methods is so helpful and informative. Thank you for taking the time to share your knowledge and experience.
The judgement of cats. They are never satisfied. Dogs are happy with the least of our efforts. Cats always demand more.
Great video very glad to see you rewire that transformer.
Keep up the great content.
Great video! Sir You are a rare combination of genius and hard work at once.
Please make a video explaining fast chargers(20w, 30w, 65w) for mobiles.
this video deserve to be in youtube rewind😁
Good job! Don't worry with the transfo, this one is like 54% bigger than the original so it can handle 50 amps easily! 🔌 💡
Excellent video! All the best
good job rewinding that transformer and improving it!!!!!!!!
Thank you for making this video, it was very informative.
Loved it! Thank you!
World's most safest transformer :D
Electrical Magic done, Diode Gone Wild Style!👍
Amazing job!💡🐈
You mad man! Love your work!
Excellent video
Nice job, well done.
Great!
I would leave the connection between parts of primary at the other end of a bobbin, to avoid that return-run back to first side. That connection would not even need a pin, it should be easy to join and isolate it somewhere far enough from secondaries connections.
That would make windings smaller and easier to fit inside the core.
Great work with that transformer.
I love how he says bobbin :D
Great job! congratulatios dioe!!
Awesome! It's like you can read my mind! I am pondering buying cheap dodgy stuff just for the fun of fixing them! You do great work :-)
Finally 😁 i was just waiting this thanks a lot diodegonewild 🙏
I learned more on this video than I did in a month of college physics!
Excellent video! Its a shame that the transformer died before you could do any efficiency measurements. I would have loved to see a before-after comparison ;-)
I kept roughly the same cross section of the windings, so the losses in the windings would probably divide by 1.6 (thats how much copper is more conductive than aluminium). The core losses would remain. But the losses in the transistors and secondary diodes are probably an order of magnitude higher that the transformer losses. I think I wouldn't even notice the difference in efficiency. The transformer losses are not the most important factor for the overall efficiency, but they are important for the reliability of it.
@@DiodeGoneWild Thinking twice about it - yes you're right. The transformer losses can't be generally very high, as it could hardly get rid of the heat anyway. So it only takes comparably small losses/little heat to destroy the transformer.
Koptan Tape, hahahaha! I am researching winding my own SMPS Flyback and within minutes you have taught me things I didn't know.
I can't wait to see the schematic of this SMPS, and listen to your great explanation of the SMPS. Please do it with your new camera :)
Nice job ! Brilliant !
Well done sir!
I was pretty sure that you'll try to rewind it. Nice job !
Greetings from Brazil, nice video!
Thanks lot dear friends good knowledge you have shared lots of love and thanks for sharing this❤❤❤❤❤
Would be fun to see you wind a massive DIY isolation transformer. Like one of those huge one that sits on the floor in a lab.
There are some great videos on TH-cam showing guys making huge 5 to 10 kV transformers using cores purchased from eBay. Would be awesome to see you make one for isolation for use in the lab. Your attention to detail is great… And some of us could really use a massive isolation transformer in our laboratory
Great explanations, thanks!
as always, thats why we follow those kind of dude, they share they knowledge and we are gratefull for that 😉
Nice job done.
Lots of information in this video!
You are the best of the best
Wow! Nicely Done! That is a thing of beauty the way you laid those wires!! :-)
I have a 30 amp version of this supply but never pull more that 12 or so amps BUT I will save this video in my "Watch Later" In case the transformer goes poof! Then I will know how to fix it... LOL
Thanks for rewinding it and making it work again. Made for a great series!
Thanks for the video!
LLAP
Very well explained
Nice job, nice video! I enjoyed it greatly and some good tips on transformer winding.
Also, it seems wise to de-rate eBay power supplies to about half the labelled current!
18:44 SCAAAAARYYY !
I was thinking the same!
NIIIIICE
Awesome well done, best video x
Nice - very informative :)
I'll put this knowledge to use rewinding some transformers from my drawer full of old chargers (which everyone has) - nothing dangerous of course though :)
No fire extinguisher????🍻🍻 Thanks for rewinding the transformer! I've requested in last video!
Sehr gut gemacht 👍
Thank you ❤️
Damn you never dedicated so much time toh a single topic
Great job!
You can put also little pill of aspirin and then put wire on top and heat this wire with soldering iron which is coated with tin. It generates no very good smell, but cleans this lacquer from copper and also makes a nice tinned result. You can't remove lacquer from very tiny cables with knife without damaging wire.
21:03 I thought so when I was younger, because it sounds logical that the turn ratio*current trough each turn should be the same constant, therefore the cross section sum should be the same, but it turns out not to be the case. The more windings a coil has, the more cross section it needs, because more turns=longer wire, therefore you need to compensate with thickness. This problem is very underlined in microwave oven transformers and any high voltage transformer. Furthermore, when making arc welder mod for MO transf. if you put 3 turns secondary with half the cross section of the primary, the primary will overheat faster.
7:41 Kapton tape (the real one at least) won't melt. Back when I was an intern at some company I'd try to burn it with soldering iron, but to no avail.
I got fake kapton tape once that actually burned with a flame when I put a 400degC iron on it.
You're right, it wont melt. The first time I saw Kapton tape, (about 40 years ago) it was being used to cover the gold plating on pcb edge connectors prior to the boards being wave soldered.
This material cannot melt fundamentally, also Chinese KOPTAN tape. But it can degrade in high heat. After a long time, more molecular bonds are broken, and it becomes brittle and crumbles. It can be rated for long term use at 150-200°C and short term use to 350°C or so, very short use for higher temp yet. Adhesive can give up with temperature too and turn darker, it's basically latex.
The smell when it burns, tho
Ugh!
250 ℃ rating of Polyamide Tape
Thanks good job sir 👍
DGW mastered High-frequency black magic. As a technician, I find it scary.
Very nice and good video.
You are monster! Love you!
Great job
Thanks 😊
When winding switch mode transformers, one must use a copper coated wire due to what’s called the skin effect where the electron flow occurs only at a thin layer at the top of the conductor. By using solid copper wire, the inner portion of the wire is not being used.
This skin effect becomes pronounced at all radio frequencies. This is what caused the development of Litz wire.
At higher power levels, copper tubing is used.
Wonderful 👍
Amazing 🤩
He makes the SAFEST Transformer in the world :)
The best thing to wake upto