Optimized Magnetics Winding Design (Part 3): Minimized Winding Resistance For Constant Winding Area

Focus:

In the first two parts of this series, magnetics winding design optimization was explained for constant layers and constant strands per turn bundle and some design formulas were given. In this third part, the most useful formulas are presented based on a fixed allotment of window area in the core to the windings. A given winding thus has fraction kww of the total core window area Aw, and the goal is to determine the optimal wire size for minimum (primary-referred) winding resistance Rwp. Using Dowell plots of bundle Fr versus penetration ratio plotted for constant winding area and other parameters, the author explains how to work backwards from acceptable winding resistance to determine the corresponding wire size in three different ranges of penetration ratio (i.e. wire size) on the Dowell plots.

What you’ll learn:

• How to determine the optimum wire size to achieve minimum winding resistance in transformer design for a constant winding-window area
• How to use Dowell’s equations and plots to minimize winding resistance in transformers given a fixed winding-window area

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Author & Publication:

Dennis Feucht, Innovatia Laboratories, Cayo, Belize, How2Power Today, Sep 15 2025

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