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thebugger
modified 9 years ago

DC Core Saturation

4
9
232
02:16:44
EC doesn't have a core saturation condition, and I've been working on a power supply where I need a choke. I substituted a choke with a tranaformer's primary but got the notion it might saturate, because it lacks an air gap. Anyway, I made the experiment, it doesn't saturate even at 130% the required current, so I'm going ahead with it, but I wanted to try and simulate a sort of a saturated core condition. A saturated core is when the core has reached its maximum flux density, and cannot withstand any further magnetization. This is a process that occurs at low frequencies, and is mainly expressed by a loss of nominal inductance, a current spike, and no further increase in energy transfer. Although the process is not abrupt, and the core can still magnetise further, the more you try to magnetise it, the more current it will demand, and the less it will become magnetised (the process will slow abruptly). DC magnetization is a major problem for SE amps, where a constant amount of direct current is always imposed on the core. It's like, it's already working on a given level, and you try to increase it further. Without an air gap most transformers saturate quickly with DC. This is a nonlinear process, and that's why an SE output transformer is always larger than a PP transformer for the same power. The air gap reduces the inductance, and they make the tranformers bigger to reintroduce some of the inductance again. A rather meaningless process if you ask me. Anyway, the transformer I'll be using is designed for a 150mA primary current and 50Hz line frequency. The reason it doesn't saturate is because saturation is a balanced process between frequency and current. Since both are twice the nominal values, it's far from its saturation point. Ok, now to the experiment. Flip the switch a few seconds after the simulation starts, and watch as the core becomes ,,saturated''. Yes it doesn't actually become saturated, but it's a close approximation. You will also notice, the core loses its regulating abilities, as the primary inductance collapses.
published 9 years ago
BillyT
9 years ago
While the description on saturation is basically correct, I think that it could be a bit too complicated for most people to understand, having worked with mag-amps and other exotic examples I do understand, but it might help if you could point to a YouTube clip.
rich11292000
9 years ago
This %130 could be related to the product's continuous duty rating of %125. When a product is intended for continuous duty, its ampacity is de-rated by %80, or increase the product's ampacity by %125. Is your %130 conclusion based on continuous duty?
rich11292000
9 years ago
Questions? 1. When we us this "balanced process" and increase the saturation level, are we increasing the overall magnetism strength?
thebugger
9 years ago
No, I meant the choke worked in my experiment on 130mA, where in reality I'll not push it further than 80mA. Rich, you might find it easier, looking at graphs but I'll try to explain it. First the core gets normally magnetised. Low level, no problem. Then the magnetization increases (sort of linearly), to a given point called the saturation point. This is the point where no further increase in current will cause further increase in flux density, e.g. the core cannot further magnetise. This is not strictly correct, because further increase in current does increase the flux density somewhat, but extremely slower than in the linear region, so for all intends of purpose, the core cannot withstand further magnetization, without severe drop in efficiency.
rich11292000
9 years ago
O well, made me think of @Nikisalli mag lev.
nikisalli
9 years ago
I use a big coil made with a nail and a lot of copper wire for that and i drive it at 18v.
thebugger
9 years ago
The iron nail might saturate easily. It's small and not processed well enough. Also you might get up to 10-20mH with that, I doubt you'll get it further.
faceblast
9 years ago
saturation is like a bucket with a hole in the bottom. if you pour water into the bucket at a steady rate, the bucket will never fill. but if you pour too fast and fill up the bucket, the bucket tips over and water goes everywhere and you are saturated.
nikisalli
9 years ago
For the next electromagnet i'm going to use a big core in the center of the coil
thebugger
9 years ago
The core is made from a special material, needs to have a given shape, and usually needs an air gap, if you're close to the saturation point. Just use an old transformer's primary and realign the core sheets (E-I), so that you have an air gap. http://www.dicks-website.eu/coilcalculator/airgap1.jpg

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