Bundle Compression Overcomes Aspect Ratio Constraints On Transformer Design

by Dennis Feucht, Innovatia Laboratories, Cayo, Belize, How2Power Today, Jun 15 2018

Focus:
Winding-window aspect ratio imposes limits on the current density and hence the transfer power that can be achieved in transformer design when using round or square wires in bundles. For bundles that are large relative to the window dimensions, window aspect ratio imposes a boundary effect that can reduce packing factor. Apart from resorting to foil, there is seemingly no solution to this problem—except for compressing the round bundles. This article explains how much the bundles be compressed and determines the extent to which low-strand-count bundles can be deformed in different configurations, leading to new freedom in winding optimization.

What you’ll learn:

• How to determine how much can wire bundles be compressed in transformer design to improve current density

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