Optimized Magnetics Winding Design (Part 2): Minimized Winding Resistance For Constant Layers Or Strands
by Optimized Magnetics Winding Design (Part 2): Minimized Winding Resistance For Constant Layers Or Strands, How2Power Today, Jul 15 2025
Focus:
In the previous part of this article, the constant-frequency eddy-current resistance ratio
Fr, which is usually plotted with constant M winding layers as a parameter, instead allows
M to vary according to various geometric constraints on the winding window such as number
of bundle strands or winding cross-sectional area. However, as was discovered in the
earlier analysis, making winding area constant did not lead to a clear minimum for Fr and
therefore provided no clarity on optimal wire size. In this article, we see how this
problem can be overcome by solving for the constant-frequency eddy-current resistance
ratio of a bundle rather than that of the individual strands. We then delve further into
how this resistance ratio varies for constant number of layers and strands.
What you’ll learn:
- How to understand how the constant-frequency eddy-current resistance ratio Fr varies for a constant number of layers or strands
- How to determine optimal wire size to minimize transformer winding losses
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