Firstly I'd just like to say this project has been a joy to read through so far and I wish you the best of luck with it, can't wait to see the results..
I'm quite interested in doing something like this myself one day but I definately need to brush up on my electronics first as the next question will probably highlight..
Just to fly off at a complete tangent here but related to transformers..
During an audit at work on our resistance welding bay, the welder was warned against ever using the transformers at 100% capacity. The auditor explained something about if flux density is too high the core becomes saturated which is very bad and the thing goes bang. Scaling the scenario down from gert spot welding machines to your project, the transformers still operate the same in principle, could maxing out the transformers be a potential issue for you?
Also if anyone could explain what exactly happens when the transformer becomes saturated in lay-mans terms that would quite interesting..
Bit of a random question but loosely relevant here I feel?
*After brushing up on Ferromagnetism I can now answer my own question, still though, are you in any danger of saturating the transformers in your project? Would be pretty nasty if they went bang
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