Determining Optimal Wire Size For Toroidal Windings

Focus:

In a previous series of articles, the design equations were derived and explained for optimizing winding design. For planar or linear (constant turns per layer) windings of EE, ETD, ETF, PQ, RM or other cores, the design formulas were easier to derive than for toroid or ring cores, where the winding layers curve to form a loop and the turns per layer decrease as layers are added. A subsequent article went further in defining the optimum operating point for toroid cores, and included formulas for determining optimal wire size for a given winding window area. This article derives the design formulas for the optimal wire size based on the Dowell equation valley point between the low and medium wire-size regions. In the previous series, this corresponded to magnetic operating-points on the curve for frv. The optimization in this article does not constrain winding area or number of bundle strands.

What you’ll learn:

• How to determine optimal wire size for minimizing winding losses in toroidal transformers and inductors

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Author & Publication:

Dennis Feucht, Innovatia Laboratories, Cayo, Belize, How2Power Today, Oct 15 2021

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