Pulse Transformer Operating Principles:

The magnetic flux in a typical A.C. transformer core Quote Request

alternates between positive and negative values. The
magnetic flux in the typical pulse transformer does not. Pulse Transformers
The typical pulse transformer operates in an “unipolar” Product Page
mode ( flux density may meet but does not cross zero.)
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A fixed D.C. current could be used to create a biasing
D.C. magnetic field in the transformer core, thereby forcing the field to cross over the zero line. Pulse
transformers usually (not always) operate at high frequency necessitating use of low loss cores (usually
ferrites). Figure 1A shows the electrical schematic for a pulse transformer. Figure 1B shows an equivalent
high frequency circuit representation for a transformer which is applicable to pulse transformers. The circuit
treats parasitic elements, leakage inductances and winding capacitance, as lumped circuit elements, but
they are actually distributed elements. Pulse transformers can be divided into two major types, power and
signal.
An example of a power pulse transformer application would be precise control of a heating element from a
fixed D.C. voltage source. The voltage may be stepped up or down as needed by the pulse transformer’s
turns ratio. The power to the pulse transformer is turned on and off using a switch (or switching device) at an
operating frequency and a pulse duration that delivers the required amount of power. Consequently, the
temperature is also controlled. The transformer provides electrical isolation between the input and output.
The transformers used in forward converter power supplies are essentially power type pulse transformers.
There exists high-power pulse transformer designs that have exceeded 500 kilowatts of power capacity.
The design of “signal” type of pulse transformer focuses on the delivery of a signal at the output. The
transformer delivers a “pulse-like” signal or a series of pulses. The turns ratio of the pulse transformer can be
used to adjust signal amplitude and provide impedance matching between the source and load. Pulse
transformers are often used in the transmittal of digital data and in the gate drive circuitry of transistors,
F.E.T.s, S.C.R.s, and etc. In the latter application, the pulse transformers may be referred to as “gate
transformers” or “gate drive transformers”. Signal type of pulse transformers handle relatively low levels of
power. For digital data transmission, transformers are designed to minimized signal distortion. The
transformers might be operated with a D.C. bias current. Many signal type pulse transformers are also
categorized as wideband transformers. Signal type pulse transformers are frequently used in communication
systems and digital networks.

Pulse transformer designers usually seek to minimize voltage droop, rise time, and pulse distortion. Droop is
the decline of the output pulse voltage over the duration of one pulse. It is cause by the magnetizing current
increasing during the time duration of the pulse. To understand how voltage droop and pulse distortion
occurs, one needs to understand the magnetizing ( exciting, or no-load ) current effects, load current effects,
and the effects of leakage inductance and winding capacitance. The designer also needs to avoid core
saturation and therefore needs to understand the voltage-time product.
Magnetizing ( No-Load ) Current, its Effects, and Its Relation to Saturation
Consider the simple pulse transformer circuit of Figure 2A and its equivalent circuit of Figure 2B.

There is no source impedance, winding capacitances, or secondary leakage inductance to worry about. With
both switches open, there cannot be any primary or secondary currents flowing. Now close the primary
switch. Since the secondary load is not connected, the pulse transformer’s primary winding acts like an
inductor placed across a voltage source. Primary current begins to flow. This is the magnetizing current ( no
secondary current ) and is governed by the differential equation V(t) = L x d(I)/dt + Rp x I(t), with units of
volts, henries, amps, and seconds. If the power supply has constant voltage, Rp = zero, & L = Lkp+Lm is
constant, the differential equation can be solved for I(t), I(t) = Io + V x t / ( Lkp+Lm ), where Io = the initial
current which equals zero. Notice that the current increases at a linear rate over time and that the rate in
inversely proportional to the inductance. The current flows through Np turns creating Np x I(t) amount of
magnetizing force ( amp-turns ) which in turns creates a magnetic flux density in the pulse transformer core.
Eventually the increasing primary magnetizing current would exceed the magnetic flux capacity of the pulse
transformer core and will saturate the core. Once saturation occurs the primary current rapidly increases
towards infinity ( in theory ). In a real circuit the primary winding resistance ( and source impedance ) would
limit the current. See Figure 3A below for graphical illustration. For non-zero Rp, I(t) = Io + ( V/Rp ) x ( 1 – e
to the ( -Rp x t / ( Lkp + Lm )) power ). The effect of Rp is graphically illustrated in Figures 3B and 3C. Rp
extends the time it takes for the unloaded transformer ( or an inductor ) to saturate. If Rp is sufficiently large,
it prevents the transformer ( or inductor ) from saturating altogether. Regardless of saturation, Rp places an
upper limit on the primary current value.
Voltage Droop
For Rp = 0 the source voltage divides proportional across Lkp and Lm hence the voltage across Lm = V x Lm
/ ( Lm+Lkp ) = Vm. The induced secondary voltage becomes equal to Ns x Vm / Np. For Rp > zero a voltage
drop occurs across Rp. The value of this drop increases in value as the primary current increases with time,
hence Vm decrease over time and consequently the secondary voltage declines over time. Thus Rp and
magnetizing current contribute to secondary voltage droop. Lkp does not contribute to the droop in the “no-
load” case but does contribute to a lower secondary starting voltage for both the “no load” and “under load”
cases. Droop is graphically illustrated in Figure 4B. Compare it against the ideal pulse shown in Figure 4A.

Voltage-time product
Pulse transformers, being typically unipolar (D.C.) applications, require the primary switch to be opened
( thereby removing the voltage source ) before saturation occurs, whereas A.C. applications reversed the
applied voltage before saturation occurs. Unipolar applications require that sufficient time be allowed to pass
to re-set the core before starting the next pulse. This time permits the magnetic field to collapse ( reset ). The
field does not completely collapse to zero value ( unless forced to zero, or lower ) because of core material
remanence. A slight air gap may be used to bring remanence closer to zero value. The gap lowers the pulse
transformer inductance. The flux range between remanence and the maximum flux is referred to as dB, the
maximum change in flux density during the pulse duration, dt. The dB of the typical pulse transformer is less
than half for that of an A.C. application because flux in A.C. applications can go from positive Bmax to
negative Bmax. Operating frequency and maximum expected temperature affect the choice of maximum
usable flux density value, Bmax. Saturation can be avoided by applying the following equation; dB x Np x Ac
x Sf = V x dt x 100000000, where dt is the maximum time duration of the pulse, Ac is the core’s cross-
sectional area and Sf is the core stacking factor ratio. Units are gausses, turns, square centimeters, volts and
seconds. Be aware that dt does not include reset time, tr. Maximum operating frequency equals 1 / ( dt + tr ).
The voltage-time product, V x dt is quite useful. The size and cost of a pulse transformer is roughly
proportional to this product.
Kickback Voltage
In the foregoing discussion the primary switch was opened thereby interrupting the current flowing through
the transformer primary. The resulting collapse in the magnetic field will induce a voltage reversal in the
transformer windings. The more rapid the field collapse is, the higher the induced voltage. The transformer
will try to dissipate the energy stored in its collapsing magnetic field. If the transformer was under load, the
induced voltage would cause current to flow into the load. In the “no-load” case of this example, the
transformer does not have any readily available place to dissipate the energy. The transformer will generate
the voltage necessary to dissipate the stored energy, hence a high voltage “kickback” ( or flyback or
backswing ) voltage will occur in the windings. In a real circuit the transformer will induce eddy currents in its
core thereby dissipating the energy as core loss. In a real circuit the high voltages can damage the switching
elements ( transistors, F.E.T.s, S.C.R.s, etc. ). Many designs include protective circuitry across the primary
winding.
Secondary Load Current Effects and Rise Time
Consider again the simple pulse transformer circuit of Figure 2A and its equivalent circuit of Figure 2B.
Initally, with both switches open, there cannot be any primary or secondary currents flowing. Close the
secondary load switch and then close the primary switch. Current flows through the primary winding. The L x
dI(t)/dt action induces a voltage in the primary winding which opposes the source voltage. A voltage, Vsi, is
also induced in the secondary winding causing secondary current to flow. The ampere-turns created by the
secondary current work against the induced voltage that opposes the source voltage. Consequently, the
source voltage supplies more current flow through the primary. Currents rapidly increase until either the
secondary current or primary current encounters a current limitation. Examples of such limits are the
secondary load and winding resistances limiting the secondary current or the source impedance and primary
winding resistance and primary leakage inductance limiting the primary current. Once a limit is encountered,
an equilibrium is quickly established except for the magnetizing current. The primary current has two
components; Irs, the load current transformed ( reflected ) to the primary winding and Im, the magnetizing
current. As in the “no-load” case, the magnetizing current starts at zero and increases over time. The pulse
transformer must be “switched off” before saturation occurs.
In this example the load is resistive, there is no secondary leakage inductance, and there is no secondary
winding capacitance; hence a purely resistive load current is reflected to the primary winding. The primary
current is larger than it was in the “no-load” case, hence more voltage drop is expected across the primary
winding resistance. Consequently less voltage, Vm, is available across Lm which results in less induced
voltage in the secondary winding. Secondary current flow through the secondary winding resistance causes
another voltage drop hence lower transformer output voltage. Under load, both the primary and secondary
winding resistance contribute to a lower secondary voltage. The secondary winding resistance does not
contribute to pulse droop.
The reflected load current, Irs, does not flow thorughthe mutual inductance, Lm, but doe flow through the
primary leakage inductance, Lkp. Lkp restricts the flow of the primary current ( hence reflected load current
also ). Consequently the reflected load current cannot immediately reach its full value ( nor can the
secondary current ). It is effectively delayed. Until the reflected load current reaches its full value, a larger
voltage drop will occur across Lkp then there was in the “no-load” case. This larger voltage diminishes in
value over time. Consequently Vm exhibits a time delay in reaching peak voltage value. This delay is also
seen in the secondary output voltage. This delay is known as rise time. Rise time is graphically illustrated in
Figure 4B.
Effects of Winding Capacitance, Secondary Leakage Inductance, and Core loss
Now consider the equivalent pulse transformer circuit of Figure 5.
The circuit has all the components of the circuit in Figure 2B, but also has primary winding capacitance,
secondary winding capacitance, core loss, and secondary leakage inductance. Start with both switches open
and no capacitive energy and no inductive energy. All currents are initially zero. Close the secondary switch
then close the primary switch. The primary leakage inductance, Lkp, restricts the flow of primary current by
opposing the source voltage. The opposing voltage is generated by Lkp x d(I)/dt action. Current flow ( from
the source ) finds the uncharged winding capacitance, Cp to be a much easier path, hence a relatively large
amount of current flows into the winding capacitance. This large amount of current could be called a surge
current because it will diminish over time as the capacitance is charged. The surge causes a relatively large
voltage drop across the primary winding resistance, Rp, thereby initially lowering the voltage available to Lkp
and Lm. Over time, as the surge current diminishes, the voltage drop across Rp diminishes, and the voltage
across Lkp and Lm reaches full ( peak ) value. The surge effectively delays the peak voltage across Lm. This
in turn delays peak secondary voltage. The delay contributes to rise time, hence Cp contributes to rise time.
As discussed earlier, Lpk restricts flow of the reflected load current and consequently also contributes to rise
time.A similar consequence occurs with the secondary winding capacitance, Cs. Any current supplied by
induced secondary voltage must charge Cs as the secondary voltage tries to rise to peak value. This delays
the secondary in reaching peak voltage, hence Cs also contributes to rise time.
Secondary leakage inductance, Lks, restricts secondary current flow just like Lkp restricted primary current
flow. Lks also delays the secondary peak output voltage, hence it also contributes to rise time.
Core loss resistance, Rc, provides a relatively small current shunt path across Lm just like the reflected
secondary load current does. It has the same effect but the effect is much smaller.
To summarize, Winding capacitances and leakage inductances act to increase rise time. ( They also
generate trailing edges which is discussed later. ) They may also contribute to spurious oscillations. In a
typical pulse transformer design, core loss does not have much effect.
The Trailing Edge
For an ideal pulse transformer, once the primary switch is opened the secondary pulse should immediately
end. This does not happen. The pulse transformer tries to dissipate the energy stored in Lm and in the
parasitic components Cp, Cs, Lkp, and Lks. The inductance will induce voltages as their magnetic fields
collapse. The capacitor charge will drain, but will not drain instantaneously. The capacitances may
temporarily supply current to the inductances. As a result, there is a sloped decline of the secondary output
voltage after the primary switch is opened. This sloped decline is referred to as the “trailing edge”. Some
combinations of capactiance and inductance could produce spurious oscillations ( known as ringing ). A
trailing edge is graphically illustrated in Figure 3B.
Pulse Distortion
Ideally the output pulse waveform should be identical in shape to the input pulse waveform except for a
desired amplitude change due to the “step-up” or “step-down” turns ratio. Any other deviation is considered
to be distortion. Rise time, droop, trailing edges, and spurious oscillations are all considered to be signal
distortions.
Figure 3B illustrates all of these distortions.
Gate Drive Transformers:
There are many types of transformers. What distinguishes a gate drive transformer from other types of
transformers? Basically, it is application! Modern day electronic circuits utilize many gated semiconductor
devices such as ordinary transistors, field effect transistors, and S.C.R.s and others. Gate drive transformers
are used in some of these circuits. A signal must be supplied to ( or removed from ) the device’s gate node to
activate ( or deactivate ) the device. When used, gate drive transformers are located within the circuitry
driving the gate. Gate drive transformers are used to modify the voltage level to the gate, provide impedance
matching, and to provide voltage isolation. Gate drive transformer may be used to deliver voltage to the grids
or plates of a vacuum tube or flash tube.
Some gate drive transformers simply deliver a voltage pulse or a series of voltage pulses to a semiconductor
gate. A gate drive transformer functioning in this manner could also be called a pulse transformer. Most
circuit designers would consider these gate drive transformers to be a type of pulse transformer. If the gate
drive transformer’s pulse initiates some action or event, the gate drive transformer could be called a trigger
transformer. Some applications require a close reproduction of the pulse. The gate transformer designer will
seek to minimize winding capacitance and leakage inductance because these parasitic components distort
the signal. This website includes information about trigger transformers and pulse transformers. The latter
includes information on the theory of operation. Click on the available links if you want to view them.
Some amplifying circuits use a gate drive transformer to deliver a signal to a semiconductor gate. Here the
objective is to reproduce the signal, but with increased power and increased voltage or current. The gate
transformer designer will seek to minimize winding capacitance and leakage inductance because these
parasitic components distort the signal. In most amplifying circuits the signal is injected into a direct current
biased transistor circuit, hence the gate transformer may have to tolerate a D.C. current bias. Even though
these gate drive transformers drive a gate, circuit designers will usually refer to them as signal transformers.
Gate drive transformers exist in a variety of shapes and sizes. There is also a wide variety of core materials
available for use with different applications. If you need more information please contact Butler Winding and
ask for Engineering.
Butler Winding can make ( and has made ) gate drive transformers. There are a wide variety of shapes and
sizes available. This includes; various standard types of “core with bobbin” structures ( E, EP, EFD, PQ, POT,
U and others ), toroids, and some custom designs. Our upper limits are 40 pounds of weight and 2 kilowatts
of power. We have experience with foil windings, litz wire windings, and perfect layering. For toroids, we can
( and have done ) sector winding, progressive winding, bank winding, and progressive bank winding. Butler
winding has a variety of winding machines, bobbin/tube and toroid. That includes two programmable
automated machines and a taping machine for toroids. Butler winding has vacuum chamber(s) for vacuum
impregnation and can also encapsulate. To ensure quality, Butler Winding purchased two programmable
automated testing machines. Most of our production is 100% tested on these machines.