Publications

Many Sandia components for military applications are designed for a 20-year life. In order to determine if magnetic components meet that requirement, the parts are subjected to selected destructive tests. This paper reviews the re-design of a power transformer and the tests required to prove-in the re-design. The re-design included replacing the Epon 828/Mica/methylenedianiline (curing agent Z) epoxy encapsulant with a recent Sandia National Laboratory (SNL) developed epoxy encapsulant. The new encapsulant reduces the Environmental Safety and Health (ES and H) hazards. Life testing of this re-designed transformer generated failures; an open secondary winding. An experimental program to determine the cause of the broken wires and an improved design to eliminate the problem was executed. This design weakness was corrected by reverting to the hazardous epoxy system.

Sandia has used flyback transformers for many years, primarily to charge capacitors for capacitive discharge units. Important characteristics of the transformer design are to meet inductance, turns ratio, and high voltage breakdown requirements as well as not magnetically saturating during each energy transfer cycle. Sandia has taken over production responsibility for magnetic components from a previous GE/LM, General Electric/Lockheed Martin, facility in Florida that produced {approximately} 50 K units per year. Vanguard Electronics is working with Sandia to transfer many of these designs to Vanguard`s small manufacturing facility in Gardena, CA. The challenge is to achieve the required high reliability and meet all the other electrical requirements with such small quantities of parts, {approximately} 100 per year. DOE requirements include high reliability {le} 3 failures per 10,000 components per 20 years while meeting numerous other environmental requirements. The basic design and prove-in required four lots of preproduction parts, extensive environmental testing, and numerous design changes. The manufacturing problems that affected performance of the transformer will be presented. These include encapsulation voids and core alignment. Also, some extended life test data that predicts long term reliability of newly produced transformers versus older designs will be compared.

Transformers models for simulation with Pspice and Analogy's Saber are being developed using experimental B-H Loop and network analyzer measurements. The models are evaluated for accuracy and convergence using several test circuits. Results are presented which demonstrate the effects on circuit performance from magnetic core losses, eddy currents, and mechanical stress on the magnetic cores.

Transformers of two different designs; and unencapsulated pot core and an encapsulated toroidal core have been modeled for circuit analysis with circuit simulation tools. We selected MicroSim`s PSPICE and Anology`s SABER as the simulation tools and used experimental BH Loop and network analyzer measurements to generate the needed input data. The models are compared for accuracy and convergence using the circuit simulators. Results are presented which demonstrate the effects on circuit performance from magnetic core losses, eddy currents, and mechanical stress on the magnetic cores.