Optimizing Winding Design For Low-Resistance Windings—Selecting Wire Or Bundle Size To Fill The Core Window

Focus:

In transformer or inductor winding design, maximizing current density in the core window maximizes power transfer. So the goal is to put as much conductive area in wire into the window area as possible. To that end, this article analyzes how to optimize winding geometry when wire size is large and turns are few—through the selection of wire size, number of layers, and bundle size. By manipulating the wire and winding parameters, we can maximize the window boundary packing factor, which leads to maximum conductive area. This discussion focuses mainly on the more challenging, low-resistance windings but also briefly discusses high-resistance windings.

What you’ll learn:

• How to optimize inductor or transformer winding geometry for maximum power transfer
• How to maximize conductive area of inductor or transformer windings by maximizing boundary packing factor
• How to maximize boundary packing factor for cases where bundle turns radius is a positive- integer submultiple of both winding-window dimensions and where it is not

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Author & Publication:

Dennis Feucht, Innovatia Laboratories, Cayo, Belize, How2Power Today, Feb 15 2024

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