private trans_calc_result_winding CalculateSecondary(double w1_R)
{
double Vout = _input.common.Vout;
trans_calc_result_winding w2 = calculateWinding(_input.common, _input.secondary);
double Vout_idle = Vout;
double Vout_load = 0;
if (_result.turns_ratio < 0.000001)
{
throw new Exception("Turns ratio hasn't been calculated");
}
double total_R = w1_R / _result.turns_ratio / _result.turns_ratio + w2.resistance;
if (_input.common.Iout_max > 0.0000000001)
{
double regulation_vdrop = _input.common.Iout_max * total_R;
if (regulation_vdrop > Vout_idle / 2)
{
throw new Exception($"Voltage drop too high: {regulation_vdrop}. Check Iout, Vout, wire ga");
}
Vout_load = Vout_idle - regulation_vdrop;
_result.Iout_max = _input.common.Iout_max;
_result.power_VA = _result.Iout_max * Vout_load;
_result.regulation = (Vout_idle - Vout_load) / Vout_idle * 100;
}
_result.Vout_idle = Vout_idle;
_result.Vout_load = Vout_load;
_result.total_eq_R = total_R;
return(w2);
}
private trans_calc_result_winding calculateWinding(trans_calc_input_common common, trans_calc_input_winding w)
{
double dl = w.awg.Diameter_m / w.w_factor;
double dh = w.awg.Diameter_m / w.w_factor;
trans_calc_result_winding res = new trans_calc_result_winding();
if (w.N_per_layer == 0)
{
w.N_per_layer = (int)(common.Core_L / dl);
if (w.N_per_layer > w.N)
{
w.N_per_layer = w.N;
}
}
if (w.N_per_layer == 0)
{
throw new Exception("Error: turns per layer calculated to zero");
}
int totalLayers = (int)(w.N / (double)w.N_per_layer);
int lastTurns = (int)w.N - (totalLayers * w.N_per_layer);
if (lastTurns == 0)
{
lastTurns = (int)w.N_per_layer;
}
else
{
++totalLayers;
}
double length_m = 0;
double turnsPerLayerSaved = w.N_per_layer;
for (int i = 0; i < totalLayers; ++i)
{
double delta = dh * (double)i;
if (i == totalLayers - 1)
{
turnsPerLayerSaved = lastTurns;
}
double p = 2.0 * (common.Core_W + common.Core_H + 2.0 * delta);
length_m += p * turnsPerLayerSaved;
}
double length_f = length_m / AWG.meters_in_foot;
double thickness = totalLayers * dh;
double resistance = w.awg.CalculateResistance(length_m, common.max_temp);
double mass = w.awg.CalculateMass_g(length_m);
res.length_m = length_m;
res.length_ft = length_f;
res.thickness_mm = thickness * 1000;
res.resistance = resistance;
res.mass = mass;
res.totalLayers = totalLayers;
res.N = w.N;
res.N_per_layer = (int)w.N_per_layer;
res.lastLayerTurns = (lastTurns == (int)w.N_per_layer) ? 0 : lastTurns;
if (w.ampacity_mil_per_amp != 0)
{
res.awg_max_current_amp = w.awg.GetCircularMils() / w.ampacity_mil_per_amp;
}
res.awg = w.awg;
return(res);
}
public trans_calc_result_text Calculate(trans_calc_input_text text_input)
{
_input.ConvertTextToInput(text_input);
double L1;
double Ae;
CalculateCommon(out L1, out Ae);
// Calculate primary
bool retry_primary = false;
int minAWG = 8;
if (_input.primary.awg == null)
{
retry_primary = true;
}
if (_input.processSecondary)
{
CalculateTurnsRatio();
CalculatePrimaryCurrent();
}
do
{
if (retry_primary)
{
_input.primary.awg = AutoSelectAWG(minAWG++, _input.isMinimizeRegulation, _input.primary, _result.Ip_full_load);
}
trans_calc_result_winding w1 = calculateWinding(_input.common, _input.primary);
w1.L = L1;
_result.primary = w1;
//Calculate secondary if configured
if (_input.processSecondary)
{
_result.Iout_max = _input.common.Iout_max;
_input.common.Core_H += w1.thickness_mm / 1000;
_input.common.Core_W += w1.thickness_mm / 1000;
bool retry_secondary = false;
minAWG = 8;
if (_input.secondary.awg == null)
{
retry_secondary = true;
}
trans_calc_result_winding w2 = null;
do
{
if (retry_secondary)
{
_input.secondary.awg = AutoSelectAWG(minAWG++, _input.isMinimizeRegulation, _input.secondary, _input.common.Iout_max);
}
w2 = CalculateSecondaryWithRetries(w1.resistance);
if (retry_secondary &&
(_input.common.WindowSize < 0.000000001 ||
w1.thickness_mm + _input.common.InsulationThickness + w2.thickness_mm
<= _input.common.WindowSize))
{
retry_secondary = false;
retry_primary = false;
}
} while (retry_secondary);
if (_result.permeability > 0.00000000001 && _result.mpath_l_m > 0.0000001)
{
w2.L = w2.N * w2.N * _result.permeability * u0 * Ae / _result.mpath_l_m;
}
_result.secondary = w2;
_result.total_thickness_mm =
w1.thickness_mm + _input.common.InsulationThickness + w2.thickness_mm;
_result.wire_total_weight = w1.mass + w2.mass;
_result.wire_csa_ratio = w1.awg.Csa_m2 / w2.awg.Csa_m2;
_result.wire_weight_ratio = w1.mass / w2.mass;
}
}while (retry_primary);
ConvertUnits();
return(new trans_calc_result_text(_result, _input));
}