Transformer Winding Design: Bundle Layer Approximation As Rings

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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Author & Publication:

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

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