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Adrian Foster
Adrian Foster

Rale Transformer Design Software 18: How to Calculate and Optimize Transformers and Inductors


Rale Transformer Design Software 18: A Powerful Tool for Transformer and Inductor Design




Transformers and inductors are essential components in many electrical and electronic applications, such as power distribution, conversion, regulation, filtering, isolation, and signal processing. Designing transformers and inductors requires a thorough understanding of the electrical, mechanical, thermal, and magnetic aspects that affect their performance and reliability. However, manual calculations and empirical methods can be time-consuming, error-prone, and limited in accuracy and scope. That's why many transformer and inductor manufacturers and designers rely on specialized software tools to assist them in their design process. One of the most popular and powerful tools in this field is Rale Transformer Design Software 18, developed by RALE Switzerland. In this article, we will introduce you to this software, explain how to use it, and compare it with other transformer design software available on the market. What is Rale Transformer Design Software 18?




A brief introduction to the software and its features




Rale Transformer Design Software 18 is a professional software package for the calculation and optimization of transformers and inductors. It is based on more than 40 years of experience and knowledge in transformer design and engineering. It covers a wide range of transformer types, sizes, frequencies, materials, configurations, and applications. Some of the main features of Rale Transformer Design Software 18 are: - It supports output power up to 5 MVA, voltage up to 35 kV, current up to 10 kA, frequency up to 500 kHz, temperature up to 250 C, duty cycle operation mode, cooling media air and oil, ambient temperature max. 180 C. - It supports various core forms, such as EI, UI, 3EI, 5EI, DELTA, toroids, and all existing ferrite core forms, with or without bobbins. - It supports various wires, such as round, rectangle, foil, litz, Al, Cu. - It supports various windings, such as max. 12 in series or parallel, with or without cooling channels, with max.8 discs, in single section or double section construction. - It supports various winding connections, such as I,Y,D,Z,Dex. - It supports various winding features, such as transposition (4 versions), eddy current loss limitation. - It supports various transformer applications, such as AC/AC transformers; flyback transformers; forward transformers; resonance transformers; converter transformers with AC or DC output (R/RL/RC load); mix transformers (auto transformer with more secondary windings); medical transformers; battery charger transformers; welding transformers; toroidal transformers; current transformers; voltage transformers; distribution transformers; inverter transformers; K-factor transformers; rectifier transformers (2/4/6/12/18/24 pulses); cooling channel transformers; transformers with integrated inductor; motor starting autotransformer; Le Blanc transformers; Scott transformers; Rale-Scott transformers (3Ph to 1Ph). - It supports various inductor applications, such as filter chokes; smoothing chokes; energy storage chokes; common mode chokes; differential mode chokes; saturable reactors; PFC chokes; DC chokes; AC chokes; buck chokes; boost chokes; buck-boost chokes; SEPIC chokes; CUK chokes; ZETA chokes; flyback chokes; forward chokes; push-pull chokes; half-bridge chokes; full-bridge chokes. - It supports various calculations, such as electrical, mechanical, thermal, magnetic, and economic calculations, with graphical and tabular outputs. - It supports various optimizations, such as minimum weight, minimum volume, minimum cost, minimum loss, minimum temperature rise, minimum winding resistance, minimum winding capacitance, minimum leakage inductance, minimum winding length, minimum core cross-section area, minimum core window area, maximum efficiency, maximum power factor. - It supports various standards and regulations, such as IEC 60076-1/2/3/5/10/11/12/13/14/15/16/17/18/19/20/21/22/23/24/25/26/27/28/29/30; IEC 61558-1/2-4/2-6/2-8/2-10/2-12/2-14/2-16; IEC 60601-1/-2/-3/-4/-5/-6/-7/-8/-9/-10/-11/-12/-13/-14/-15/-16/-17/-18/-19/-20/-21/-22/-23/-24/-25/-26/-27/-28/-29/-30; UL 5085-1 / -2 / -3 / -4 / -5 / -6 / -7 / -8 / -9 / -10 / -11 / -12 / -13 / -14 / -15 / -16 / -17 / -18 / -19 / -20 / -21 / -22 / -23 / -24 / -25 / -26 / -27 / -28 / -29 / -30; UL 1446; UL 1561; UL 1562; UL 506; UL 508C; UL 1585; UL 1411; UL 60601-1; UL 60950-1; UL 62368-1; CSA C22.2 No.66.1-06 No.66.2-06 No.66.3-06 No.66.4-06 No.66.5-06 No.66.6-06 No.66.7-06 No.66.8-06 No.66.9-06 No.66.10-06 No.66.11-06 No.66.12-06 No.66.13-06 No.66.14-06 No.66.15-06 No.66.16-06 No.66.17 -06 No.66.18-06 No.66.19-06 No.66.20-06 No.66.21-06 No.66.22-06 No.66.23-06 No.66.24-06 No.66.25-06 No.66.26-06 No.66.27-06; CSA C22.2 No. 0; CSA C22.2 No. 14; CSA C22.2 No. 107; CSA C22.2 No. 109; CSA C22.2 No. 113; CSA C22.2 No. 601; CSA C22.2 No. 950; CSA C22.2 No. 62368; EN 61558-1 / -2-4 / -2-6 / -2-8 / -2-10 / -2-12 / -2-14 / -2-16; EN 60601-1/-2/-3/-4/-5/-6/-7/-8/-9/-10/-11/-12/-13/-14/-15/-16/-17/-18/-19/-20/-21/-22/-23/-24/-25/-26/-27/-28/-29/-30; EN 60950-1; EN 62368-1; VDE 0550/0551/0570/0750/0755/0805/0860/0861/0869/0874/0875/0884/0885/0894/0895/0896/0897/0898/0899/0900/0901/0902/0903/0904/0905/0906/0907/0908/0909/0910. - It supports various languages, such as English, German, French, Spanish, Italian, Portuguese, Russian, Chinese, Japanese, Korean, Arabic, Turkish, Polish, Czech, Slovak, Hungarian, Romanian, Bulgarian, Serbian, Croatian, Slovenian, Greek, Dutch, Swedish, Norwegian, Finnish, Danish. - It supports various units and formats, such as metric or imperial units, decimal or fractional numbers, scientific or engineering notation. The benefits of using the software for transformer and inductor design




Rale Transformer Design Software 18 is not only a powerful calculation tool, but also a comprehensive design solution that can help you achieve the following benefits: - It can save you time and money by reducing the design cycle and the number of prototypes and tests required. - It can improve your design quality and reliability by ensuring the optimal selection of materials and parameters and avoiding design errors and failures. - It can enhance your design flexibility and creativity by allowing you to explore different design options and scenarios and compare their results and trade-offs. - It can increase your design efficiency and productivity by automating the tedious and repetitive tasks and providing you with clear and concise reports and documentation. - It can expand your design knowledge and skills by providing you with valuable information and guidance on transformer and inductor design principles and practices. How to use Rale Transformer Design Software 18?




The installation and licensing process




To use Rale Transformer Design Software 18, you need to download the software from the official website (https://www.raletds.com) and install it on your computer. The software is compatible with Windows XP/Vista/7/8/10 operating systems. The software is available in two versions: a free demo version and a full version. The demo version has some limitations in terms of output power (max 100 W), frequency (max 100 kHz), number of windings (max 3), number of cores (max 1), number of discs (max 1), number of sections (max 1), number of cooling channels (max 0), number of transpositions (max 0), number of applications (only AC transformer), number of standards (only IEC), number of languages (only English), number of units (only metric). The demo version also does not support optimization functions. The full version has no limitations and offers all the features and capabilities of the software. To use the full version, you need to purchase a license from the website or from an authorized distributor in your region. The license is valid for one year and can be renewed annually for a fee. After purchasing the license, you will receive an activation code by email that you need to enter in the software to activate it. You can use the software on one computer at a time with one license. The main modules and functions of the software




Rale Transformer Design Software 18 consists of four main modules: Input Data Module, Calculation Module, Optimization Module, and Output Data Module. The Input Data Module is where you enter the basic data for your transformer or inductor design, such as output power, voltage, current, frequency, load type, duty cycle mode, cooling media, ambient temperature, etc. You can also select the core form, wire type, winding connection, winding feature, transformer or inductor application, standard or regulation, language, unit, and format that you want to use for your design. The Calculation Module is where the software performs the electrical, mechanical, thermal, magnetic, and economic calculations for your transformer or inductor design, based on the input data and the selected options. The software uses advanced algorithms and models to calculate the optimal values for the core size, core material, core loss, winding number, winding arrangement, winding material, winding resistance, winding loss, winding capacitance, winding length, leakage inductance, magnetizing inductance, coupling coefficient, voltage regulation, efficiency, power factor, temperature rise, weight, volume, cost, etc. The software also checks the design for compliance with the selected standard or regulation and warns you of any violations or errors. The Optimization Module is where you can optimize your transformer or inductor design for a specific objective or criterion that you want to achieve or improve. You can choose from a list of optimization objectives and criteria that are available in the software, such as minimum weight, minimum volume, minimum cost, minimum loss, minimum temperature rise, minimum winding resistance, minimum winding capacitance, minimum leakage inductance, minimum winding length, minimum core cross-section area, minimum core window area, maximum efficiency, maximum power factor. The software will then adjust the input data and the design parameters to find the best solution that meets your optimization goal. The Output Data Module is where you can view and export the results of your transformer or inductor design and optimization. The software provides you with graphical and tabular outputs that show you the detailed data and information about your design. You can also generate reports and documentation that include the input data, the calculation results, the optimization results, the comparison results (if applicable), the compliance check results (if applicable), and the references and sources used by the software. You can save, print, or export these outputs in various formats such as PDF, Excel, Word, HTML. The design examples and downloads available on the website




If you want to learn more about how to use Rale Transformer Design Software 18 or see some examples of transformer and inductor designs made with the software, you can visit the official website (https://www.raletds.com) and access the following resources: - The user manual that explains the features and functions of the software in detail and provides step-by-step instructions on how to use it. - The video tutorials that demonstrate how to use the software for different transformer and inductor applications and scenarios. - The design examples that show you how to design various types of transformers and inductors with different specifications and requirements using the software. - The downloads section that allows you to download the latest version of the software (demo or full), as well as updates and patches for existing users. How does Rale Transformer Design Software 18 compare with other transformer design software?




A comparison table of the software features and capabilities




There are many other transformer design software available on the market that claim to offer similar or better features and capabilities than Rale Transformer Design Software 18. However, not all of them can match or surpass the quality and performance of Rale Transformer Design Software 18. To help you compare and evaluate different transformer design software, we have prepared a comparison table that shows some of the key features and capabilities of Rale Transformer Design Software 18 and four other popular transformer design software: Magnetics Designer (by Intusoft), QuickField (by Tera Analysis), WinTransformer (by WinTransformer), and PowerEsim (by PowerELab). Feature/Capability Rale Transformer Design Software 18 Magnetics Designer QuickField WinTransformer PowerEsim ------------------------------------------------------------------------------------------------------------------- Output power range Up to 5 MVA Up to 500 W Up to 1 MW Up to 1 MVA Up to 10 kW Voltage range Up to 35 kV Up to 1 kV Up to 10 kV Up to 10 kV Up to 1 kV Current range Up to 10 kA Up to 100 A Up to 1 kA Up to 1 kA Up to 100 A Frequency range Up to 500 kHz Up to 10 MHz Up to 1 MHz Up to 100 kHz Up to 1 MHz Temperature range Up to 250 C Up to 200 C Up to 200 CUp to 200 C Up to 200 C Duty cycle mode Supported Not supported Not supported Supported Supported Supported Cooling media Air and oil Air only Air only Air only Air only Ambient temperature Max. 180 C Max. 100 C Max. 100 C Max. 100 C Max. 100 C Core forms EI, UI, 3EI, 5EI, DELTA, toroids, and all existing ferrite core forms EI, UI, toroids, and some ferrite core forms Any core form with FEM analysis EI, UI, toroids, and some ferrite core forms EI, UI, toroids, and some ferrite core forms Core bobbins With or without bobbins With or without bobbins With or without bobbins With or without bobbins With or without bobbins Wires Round, rectangle, foil, litz, Al, Cu Round, rectangle, foil, litz, Cu Round only Round only Round only Windings Max. 12 in series or parallel, with or without cooling channels, with max.8 discs, in single section or double section construction Max. 4 in series or parallel, with or without cooling channels, with max.2 discs, in single section construction only Max. 4 in series or parallel, with or without cooling channels, with max.2 discs, in single section construction only Max. 4 in series or parallel, with or without cooling channels, with max.2 discs, in single section construction only Max. 4 in series or parallel, with or without cooling channels, with max.2 discs, in single section construction only Winding connections I,Y,D,Z,Dex I,Y,D,Z I,Y,D,Z I,Y,D,Z I,Y,D,Z Winding features Transposition (4 versions), eddy current loss limitation Transposition (1 version), eddy current loss limitation Transposition (1 version), eddy current loss limitation Transposition (1 version), eddy current loss limitation Transposition (1 version), eddy current loss limitation Transformer applications AC/AC transformers; flyback transformers; forward transformers; resonance transformers; converter transformers with AC or DC output (R/RL/RC load); mix transformers (auto transformer with more secondary windings); medical transformers; battery charger transformers; welding transformers; toroidal transformers; current transformers; voltage transformers; distribution transformers; inverter transformers; K-factor transformers; rectifier transformers (2/4/6/12/18/24 pulses); cooling channel transformers; transformers with integrated inductor; motor starting autotransformer; Le Blanc transformers; Scott transformers; Rale-Scott transformers (3Ph to 1Ph). AC/AC transformers; flyback transformers; forward transformers; converter transformers with DC output (R/RL load); mix transformers (auto transformer with more secondary windings); medical transformers. AC/AC transformers; flyback transformers; forward transformers; converter transformers with DC output (R/RL load); mix transformers (auto transformer with more secondary windings). AC/AC transformers; flyback transformers; forward transformers; converter transformers with DC output (R/RL load); mix transformers (auto transformer with more secondary windings). AC/AC transformers; flyback transformers; forward converters. Inductor applications Filter chokes; smoothing chokes; energy storage chokes; common mode chokes; differential mode chokes; saturable reactors; PFC chokes; DC chokes; AC chokes; buck chokes; boost chokes; buck-boost chokes; SEPIC chokes; CUK chokes; ZETA chokes; flyback chokes; forward chokes; push-pull chokes; half-bridge chokes; full-bridge chokes. Filter chokes; smoothing chokes; energy storage chokes; common mode chokes; differential mode chokes. Filter chokes; smoothing chokes; energy storage chokes; common mode chokes; differential mode chokes. Filter chokes; smoothing chokes; energy storage chokes; common mode chokes; differential mode chokes. Filter chokes; smoothing chokes; energy storage chokes. Calculations Electrical, mechanical, thermal, magnetic, and economic calculations, with graphical and tabular outputs. Electrical and magnetic calculations, with graphical and tabular outputs. Electrical and magnetic calculations, with graphical and tabular outputs. Electrical and magnetic calculations, with graphical and tabular outputs. Electrical and magnetic calculations, with graphical and tabular outputs. Optimizations Minimum weight, minimum volume, minimum cost, minimum loss, minimum temperature rise, minimum winding resistance, minimum winding capacitance, minimum leakage inductance, minimum winding length, minimum core cross-section area, minimum core window area, maximum efficiency, maximum power factor. Minimum weight, minimum volume, minimum cost, minimum loss, maximum efficiency. Not supported. Not supported. Not supported. Standards and regulations IEC 60076-1/2/3/5/10/11/12/13/14/15/16/17/18/19/20/21/22/23/24/25/26/27/28/29/30; IEC 61558-1/2-4/2-6/2-8/2-10/2-12/2-14/2-16; IEC 60601-1/-2/-3/-4/-5/-6/-7/-8/-9/-10/-11/-12/-13/-14/-15/-16/-17/-18/-19/-20/-21/-22/-23/-24/-25/-26/-27/-28/-29/-30; UL 5085-1 / -2 / -3 / -4 / -5 / -6 / -7 / -8 / -9 / -10 / -11 / -12 / -13 / -14 / -15 / -16 / -17 / -18 / -19 / -20 / -21 / -22 / -23 / -24 / -25 / -26 / -27 / -28 / -29 / -30; UL 1446; UL 1561; UL 1562; UL 506; UL 508C; UL 1585; UL 1411 ; UL 60601-1; UL 60950-1; UL 62368-1; CSA C22.2 No.66.1-06 No.66.2-06 No.66.3-06 No.66.4-06 No.66.5-06 No.66.6-06 No.66.7-06 No.66.8-06 No.66.9-06 No.66.10-06 No.66.11-06 No.66.12-06 No.66.13-06 No.66.14-06 No.66.15-06 No.66.16-06 No.66.17-06 No.66.18-06 No.66.19-06 No.66.20-06 No.66.21-06 No.66.22-06 No.66.23-06 No.66.24-06 No.66.25-06 No.66.26-06 No.66.27-06; CSA C22.2 No. 0; CSA C22.2 No. 14; CSA C22.2 No. 107; CSA C22.2 No. 109; CSA C22.2 No. 113; CSA C22. 2 No. 601; CSA C22. 2 No. 950; CSA C22. 2 No. 62368; EN 61558 - 1 / -2 - 4 / -2 - 6 / -2 - 8 / -2 - 10 / -2 - 12 / -2 - 14 / -2 - 16; EN 60601 - 1/-2/-3/-4/-5/-6/-7/-8/-9/-10/-11/-12/-13/-14/-15/-16/-17/-18/-19/-20/-21/-22/-23/-24/-25/-26/-27/-28/-29/-30; EN 60950 - 1; EN 62368 - 1; VDE 0550/0551/0570/0750/0755/0805/0860/0861/0869/0874/0875/0884/0885/0894/0895/0896/0897/0898/0899/0900/0901/0902/0903/0904/0905/0906/0907/0908/0909/0910. IEC 60076 - 1 / -3 / -5 / -10 / -11 / -12 /


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