Optimized Magnetics Winding Design (Part 2): Minimized Winding Resistance For Constant Layers Or Strands

Focus:

In the previous part of this article, the constant-frequency eddy-current resistance ratio Fr, which is usually plotted with constant M winding layers as a parameter, instead allows M to vary according to various geometric constraints on the winding window such as number of bundle strands or winding cross-sectional area. However, as was discovered in the earlier analysis, making winding area constant did not lead to a clear minimum for Fr and therefore provided no clarity on optimal wire size. In this article, we see how this problem can be overcome by solving for the constant-frequency eddy-current resistance ratio of a bundle rather than that of the individual strands. We then delve further into how this resistance ratio varies for constant number of layers and strands.

What you’ll learn:

• How to understand how the constant-frequency eddy-current resistance ratio Fr varies for a constant number of layers or strands
• How to determine optimal wire size to minimize transformer winding losses

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Author & Publication:

Optimized Magnetics Winding Design (Part 2): Minimized Winding Resistance For Constant Layers Or Strands, How2Power Today, Jul 15 2025

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