Optimized Magnetics Winding Design (Part 3): Minimized Winding Resistance For Constant Winding Area
by Dennis Feucht, Innovatia Laboratories, Cayo, Belize, How2Power Today, Sep 15 2025
Focus:
In the first two parts of this series, magnetics winding design optimization was explained
for constant layers and constant strands per turn bundle and some design formulas were
given. In this third part, the most useful formulas are presented based on a fixed
allotment of window area in the core to the windings. A given winding thus has fraction
kww of the total core window area Aw, and the goal is to determine the optimal wire size
for minimum (primary-referred) winding resistance Rwp. Using Dowell plots of bundle Fr
versus penetration ratio plotted for constant winding area and other parameters, the
author explains how to work backwards from acceptable winding resistance to determine the
corresponding wire size in three different ranges of penetration ratio (i.e. wire size) on
the Dowell plots.
What you’ll learn:
- How to determine the optimum wire size to achieve minimum winding resistance in transformer design for a constant winding-window area
- How to use Dowell’s equations and plots to minimize winding resistance in transformers given a fixed winding-window area
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