Resonant / ZVS Push-Pull Transformer Design Request

SolidMagnetics Design Automation

Resonant Converter Transformer Design Request

Use this form for LLC, SRC, LCC, CLLC, ZVS/Mazzilli, Royer, and driven push-pull transformer designs. Required fields define the electrical and safety envelope; advanced fields preserve existing circuit values or impose design limits.

Gold fields and notices identify important decisions. Copper-colored text identifies winding and construction considerations.

Contact / Job Information

Enter a recognizable project or design name.

Converter Architecture and Electrical Requirements

Select whether SolidMagnetics must preserve an existing circuit or may determine the resonant tank and transformer together.
This field is the authoritative converter subtype used by the API/Core calculation mapper.
Select the source feeding the resonant power stage, not the upstream AC wall voltage unless the converter directly uses it.
Minimum DC voltage at the converter power stage.
Nominal design-point DC voltage.
Maximum continuous DC voltage at the converter power stage.
Optional short-duration maximum input transient seen by the converter.
Final Required Output Type / Voltage Basis
Select the basis of the voltage entered below. This is required at every voltage level.
Final load voltage. If a multiplier is used, enter the voltage after the multiplier.
Maximum allowed steady-state deviation from the nominal final output voltage.
Minimum regulated or expected load current, using the unit selected below.
Nominal continuous output current, using the unit selected below.
Maximum required peak output current, using the same unit. Enter the continuous value if no overload is required.
The selected unit applies to the minimum, nominal, and peak main-output current values.
Calculated from nominal final output voltage and nominal output current. Additional output rails are not included.
Calculated from nominal final output voltage and peak output current.
Output Operating Mode
Select the operating mode at any voltage level.
Optional. Enter the maximum acceptable no-load or light-load output voltage.

Output Windings, Rectification, and Loads

Enter the number of required main secondary output rails. Do not count a small controller-bias winding.
Select the required electrical arrangement of the transformer secondary winding or windings.
A bare transformer produces AC. Select the integrated assembly choice only if rectifiers are part of the requested deliverable.
Rectifier topology changes the required secondary turns, RMS current, copper loss, and diode-drop allowance.
Optional. Enter the total forward drop in the active rectifier path at rated load, or leave blank for automatic estimation.
Load behavior affects the reflected resistance, resonant gain requirement, current stress, regulation, and fault behavior.
Optional. Describe load steps, startup capacitance, battery range, discharge cycle, constant-current behavior, negative resistance, or other nonlinear behavior.
Optional total output capacitance relevant to startup, transient, and short-circuit behavior.

Switching, Drive, and Resonant-Tank Requirements

Lowest switching frequency over input, load, startup, and control range.
Nominal design frequency.
Highest switching frequency over input, load, startup, and control range.
Auto calculate is recommended unless the converter has a contractual minimum-efficiency requirement.
Select the physical/electrical primary arrangement, not merely the switching topology.
Select the closest description of the voltage exciting the transformer/tank.
Optional but strongly recommended for an existing converter. Enter the controller or gate-driver device.
Optional worst-case ripple on the converter input bus.
Fixed and target modes reveal the value and tolerance fields below.
Select whether the transformer deliberately provides all, part, or none of the series resonant inductance.
Leakage is a controlled design variable in many resonant transformers rather than an unconditional defect.
Optional target transformer leakage measured with the specified winding(s) shorted.
Optional acceptance tolerance for the transformer leakage-inductance target.
Optional expert override. Leave blank for automatic turns-ratio calculation.
Resonant design note
The transformer will be evaluated as part of the resonant network. Flyback energy-storage equations will not be used. Turns ratio, Lm, leakage/Lr, winding capacitance, frequency range, ZVS/ZCS margin, loss, temperature, and buildability must be checked together.

Electrical Acceptance Limits and Parasitics

Optional measured or circuit-simulation constraint. Leave blank when SolidMagnetics should calculate it.
Optional winding RMS-current constraint before rectification. Leave blank when it should be calculated.
Optional winding resistance acceptance limit at the specified reference temperature.
Optional winding resistance acceptance limit at the specified reference temperature.
Optional interwinding-capacitance limit used for EMI and common-mode-current optimization.
A shield can reduce common-mode coupling but may increase complexity and affect capacitance, loss, and pin requirements.
Describe startup behavior, maximum overload, current-limit behavior, open-load operation, short-circuit behavior, burst mode, and any required ride-through conditions.
Optional duration the magnetics must withstand before protection removes or limits power.

Isolation, Safety, and Compliance Requirements

The end-product category determines which safety standard and insulation rules apply.
Safety / Product Standard Target
Select every known target. Enter edition, amendment, customer specification, and special clauses below.
Optional but strongly recommended. List the exact standard edition, amendments, insulation table/section, customer document, or required construction system.
Environmental / Material Compliance

Core, Thermal, and Mechanical Constraints

Gap selection affects Lm, fringing loss, leakage, and the feasibility of integrated resonant magnetics.
Optional manufacturer, core set, material grade, bobbin part number, or approved-parts-list restriction.
Lowest specified operating ambient temperature.
Highest specified operating ambient temperature.
Maximum winding or component temperature rise above ambient.
Optional absolute winding hot-spot limit. Leave blank to derive from insulation system and margin.
Leave blank if unconstrained.
Leave blank if unconstrained.
Leave blank if unconstrained.

Winding, Termination, and Manufacturing Preferences

SolidMagnetics may override Auto based on leakage, capacitance, safety, fill, loss, and manufacturability.
Potting or Encapsulation Requirement
Optional total pin or terminal count.
Optional center-to-center pin spacing.
List primary, secondary, center-tap, shield, auxiliary, start/finish, and no-connect pin requirements. Include dot polarity where known.
Include Auxiliary / Bias Winding?
Volume helps balance custom construction, tooling, standard parts, labor, and cost.
The selected mode is the primary preset. The sliders below are secondary optimization weights.

Advanced Design Preference Weights

Selected Value: 50
Higher values favor a smaller transformer even if loss or temperature margin is reduced.
Selected Value: 70
Higher values favor lower total core, copper, dielectric, and proximity-effect loss.
Selected Value: 70
Higher values favor cooler operation and greater thermal margin.
Selected Value: 40
Higher values favor common parts, simpler construction, and lower material/labor cost.
Selected Value: 70
Higher values enforce the requested leakage objective more strongly.
Selected Value: 80
Higher values favor additional creepage, clearance, insulation, and dielectric margin.
Selected Value: 70
Higher values favor simpler winding structures, reasonable fill, repeatability, and production testing.
Selected Value: 60
Higher values favor controlled capacitance, shielding, reduced ringing, and quieter winding construction.

Supporting Files and Final Requirements

Drag & Drop Files, Choose Files to Upload You can upload up to 8 files.
Optional. Upload converter schematics, controller information, SPICE results, measured waveforms, existing transformer data, drawings, pinouts, or enclosure constraints.
Include remaining requirements such as preferred material grade, maximum flux density, winding-current density, DCR reference temperature, partial-discharge limits, acoustic-noise limits, shielding, layer construction, tolerances, agency notes, or commercial constraints.
Design Input Confirmation
SolidMagnetics calculations and CAD generation will use these values as the design contract.