A New Method Of Winding Design Optimization (Part 1): Window Geometry And Eddy-Current Plots
by Dennis Feucht, Innovatia Laboratories, Cayo, Belize, How2Power Today, Sep 15 2017
Focus:
This article series presents new advances in the simplification and refinement of
winding design for transformers and inductors, and also its conceptual extension into
new territory. At first, winding design seems unduly complicated by fields equations
and winding geometry. However, the right paths through the mathematics can greatly
simplify the derivation of algebraic design equations that can then be used with a
calculator. This part 1 article begins by reviewing the use of Dowell-equation graphs
to minimize winding losses due to eddy-current effects in transformer and inductor
design through selection of wire size, number of strands per bundle, and indirectly,
the number of winding layers. The rest of the article then discusses how these three
parameters are constrained while attempting to minimize winding resistance. It also
analyzes how holding certain factors constant such as winding area, number of strands,
and number of strand layers affects the choice of operating points on the Dowell-
equation graphs and demonstrates these effects with plots for a selected example core.
What you’ll learn:
- How to use Dowell-equation graphs to minimize winding losses due to eddy-current effects in transformer and inductor design through selection of wire size, number of strands per bundle, and number of winding layers.
- How to minimize winding losses in transformer inductor design given a constant winding area, number of strands, or number of strand layers
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