Transformer Winding Design: Bundle Layer Approximation As Rings
by Dennis Feucht, Innovatia Laboratories, Cayo, Belize, How2Power Today, Sep 15 2021
Focus:
Wire bundles consist of strands of individual wire conductors bound together and wound as
turns in a winding of a magnetic component such as a transformer. Having less than five
strands minimizes the proximity effect within a bundle when twisted. Some bundles have
many more than five strands, and within the bundle, those strands form the same kind of
pattern as wire wound in layers in a winding, with the same packing properties. With
multiple layers of strands within a bundle, the proximity effect becomes significant. To
estimate what it might be from Dowell’s equation some estimate of the number of layers of
strands, Ms, within the bundle is needed. This article derives various formulas for
estimating Ms and gives rationales for them. Methods defined here include layer
approximation by semi-circles of rings, by bundle radius, and by bundle and strand
areas.
What you’ll learn:
- How to estimate the number of layers in a wire bundle to analyze proximity effects and minimize transformer winding losses
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