esigned to operate at low frequencies, the windings are usually formed around an iron or steel core. This helps to confine the magnetic field within the transformer and increase its efficiency, although the presence of the core causes energy losses. Transformers made to operate at high frequencies may use other lower loss materials, or may use an air core.
Power transformers are further classified by the exact arrangement of the core and windings as "shell type", "core type" and also by the number of "limbs" that carry the flux (3, 4 or 5 for a 3-phase transformer). The differences in the performance of each of these types, while of continuing interest to specialists, is perhaps more detail than is appropriate for a general encyclopedia.
Steel cores Edit
Transformers often have silicon steel cores to channel the magnetic field. This keeps the field more concentrated around the wires, so that the transformer is more compact. The core of a power transformer must be designed so that it does not reach magnetic saturation. Carefully designed gaps are sometimes placed in the magnetic path to help prevent saturation. Practical transformer cores are always made of many stamped pieces of thin steel. The high resistance between layers reduces eddy currents in the cores that waste power by heating the core. These are common in power and audio circuits. A typical laminated core is made from E-shaped and I-shaped pieces, leading to the name "EI transformer". One problem with a steel core is that due to the material's magnetic hysteresis it may retain a static magnetic field when power is removed. When power is then reapplied, the residual field may cause the core to temporarily saturate. This can be a significant problem in transformers of more than a few hundred watts output, since the higher inrush current can cause mains fuses to blow unless current-limiting circuitry is added. More seriously, inrush currents can physically deform and damage the primary windings of large power transformers.
Solid cores Edit
In higher frequency circuits such as switch-mode power supplies, powdered iron cores are sometimes used. These materials combine a high magnetic permeability with a high material resistivity. At even higher frequencies (radio frequencies typically) other types of core made of non-conductive magnetic materials, such as various ceramic materials called ferrites are common. Some transformers in radio-frequency circuits have adjustable cores which allow tuning of the coupling circuit.
Air cores Edit
High-frequency transformers may also use air cores. These eliminate the loss due to hysteresis in the core material. Such transformers maintain high coupling efficiency (low stray field loss) by overlapping the primary and secondary windings.
Toroidal cores Edit
Toroidal transformers are built around a ring-shaped core, which is made from a long strip of silicon steel or permalloy wound into a coil, or from ferrite, depending on frequency. This construction ensures that all the grain boundaries are pointing in the optimum direction, making the transformer more efficient by reducing the core's reluctance, and eliminates the air gaps inherent in the construction of an EI core. The cross-section of the ring is usually square or rectangular, but more expensive cores with circular cross-sections are also available. The primary and secondary coils are wound concentrically to cover the entire surface of the core. This minimises the length of wire needed, and also provides screening to prevent the core's magnetic field from generating electromagnetic interference.
Toroidal cores for use at frequencies up to a few tens of kilohertz may also be made of ferrite material to reduce losses. Such transformers are used in switch-mode power supplies.
Toroidal transformers are more efficient (around 95%) than the cheaper laminated EI types. Other advantages, compared to EI types, include smaller size (about half), lower weight (about half), less mechanical hum (making them superior in audio amplifiers), lower exterior magnetic field (about one tenth), lo