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.

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.