I may end up winding some transformers and was considering validator formation as I have some material that may work well for the iron core. I'm considering using Olympic specification weight plates which have a 2" (or there abouts) center hole for the barbell. My plates are made of cast iron but I can also get plates made of steel in 1.25, 2.5, 5, 10, 25, 35 45 and 100lb increments. I'm not planning on anything larger than maybe the 10lb plate (about 7-8" diam) if I decide to make a large transformer.
Anyone who has looked at how transformers are made can see that toroidal are more difficult to make than using the E form plates and a bobbin. From what I have seen, it looks like many lengths of wire are used in serial to form each winding and they solder them together.
Here are some videos on how it can be done:
Machine process
Manual - This guy has a neat idea on the process!!
What I am wondering is whether cutting a slot from the center of the plate to the outer edge so the wire can pass through, allowing the winding to happen much easier, will have an effect on the transformer performance. The width of the cut would only be as wide as necessary for the wire to pass through so I would say 1/8" at most probably more like 1/10" inch. After winding is finished a piece of steel could be placed in the gap and tack welded in place IF TOTALLY necessary but since it could damage wire insulation/enamel I would really like to avoid this.
Another question is whether steel of cast iron is better. IDK what kind of steel it is, I suspect it is low carbon and pretty soft (in comparison to tool steel) as it is made for being a weight, not as a high speed cutting tool. It should be made to not chip when hit against other plates and such, so it should be soft.
how much iron or steel is necessary? I've read that microwave oven transformers reach saturation point because they don't use enough steel/iron and I'm not sure what effect this has and where more iron is needed to make the transformer "better" - middle, sides/surrounding, etc. Does more iron allow more wattage handling/production?
The reason I a looking at using the weights is because the total weight of the transformer isn't really an issue and in a could cases, the more heat it can dissipate the better. The last pic of the had dumbell I was wondering if something like that could be used as the iron core with the primary wrapped around the handle and then the secondary wrapped around the finished primary. My only concern is heat in the primary and what purpose the weight ends will have on the transformer.
Anyone who has looked at how transformers are made can see that toroidal are more difficult to make than using the E form plates and a bobbin. From what I have seen, it looks like many lengths of wire are used in serial to form each winding and they solder them together.
Here are some videos on how it can be done:
Machine process
Manual - This guy has a neat idea on the process!!
What I am wondering is whether cutting a slot from the center of the plate to the outer edge so the wire can pass through, allowing the winding to happen much easier, will have an effect on the transformer performance. The width of the cut would only be as wide as necessary for the wire to pass through so I would say 1/8" at most probably more like 1/10" inch. After winding is finished a piece of steel could be placed in the gap and tack welded in place IF TOTALLY necessary but since it could damage wire insulation/enamel I would really like to avoid this.
Another question is whether steel of cast iron is better. IDK what kind of steel it is, I suspect it is low carbon and pretty soft (in comparison to tool steel) as it is made for being a weight, not as a high speed cutting tool. It should be made to not chip when hit against other plates and such, so it should be soft.
how much iron or steel is necessary? I've read that microwave oven transformers reach saturation point because they don't use enough steel/iron and I'm not sure what effect this has and where more iron is needed to make the transformer "better" - middle, sides/surrounding, etc. Does more iron allow more wattage handling/production?
The reason I a looking at using the weights is because the total weight of the transformer isn't really an issue and in a could cases, the more heat it can dissipate the better. The last pic of the had dumbell I was wondering if something like that could be used as the iron core with the primary wrapped around the handle and then the secondary wrapped around the finished primary. My only concern is heat in the primary and what purpose the weight ends will have on the transformer.