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Abstract- The one well-known one-dimensional method for At dc, the resistances are equal, although at high fre-
calculating the ac resistance of multilayer windings contains a quencies, the square representation of round conductors
built-in orthogonality which has not been reported previously. becomes inaccurate.
Orthogonality between skin effect and proximity effect makes a
more generalized approach for the analytical solution of ac resis- 4) The skin depth is made a function of the axial packing
tance in windings possible. This includes a method to calculate factor. Obviously, something as fundamental as skin
the ac resistance of round conductor windings which is not only depth cannot be a function of geometry.
convenient to use, but gives more accurate ansers than the basic Despite these shortcomings, this method received much
one-dimensional method because the exact analytical equations
for round conductors can be used. attention during recent years to such an extent that an overview
paper [6] was presented. In this paper, it will be shown that
it is possible to overcome the above shortcomings within the
I. ANALYTICALCALCULATION OF COPPER LOSSES scope of an exact analytical approach, and a more generalized
10
RAC
Rdc
2 <
cosh - COS (
where
Fig. 2. Magnetic field intensity at the boundaries of two adjacent sets of foil
conductors (according to Amptres circuital law). E = - -f, i d
2 6
0 0 Although (1) and ( 2 ) give the same dc resistance, the approx-
imation with rectangular conductors (2) becomes optimistic at
high frequencies, as can be seen from the graph in Fig. 4.
For example, even at f n o r m = 10 (i.e., the frequency where
the skin depth is one tenth the wire diameter), the rectangular
approximation overpredicts by 16%. It is evident from this
graph that even for a single conductor configuration, significant
* improvement is obtained by opting for the cylindrical solution
+ U=- t instead of the equal area one-dimensional solution.
a) b) S+t C ) d)
Fig. 3. Representation of round conductors in terms of the one-dimensional BETWEENSKINEFFECT
IV. ORTHOGONALITY
model: a) foil conductor, b) foil consisting of square conductors, c) spaced
square conductors, d) equal area round conductors. AND PROXIMITY EFFECTIN CONDUCTORS
5 ) Average magnetic field across mth square conductor Orthogonality exists between skin effect and proximity
layer = ~ ( -m+)If. effect when the applied magnetic field due to other conductors
The frequency response and conductor dimensions (proximity field) is assumed to be uniform over the conductor
have been normalized in the paper by introducing a cross section. This permits decoupling of the two effects
normalized frequency as follows: and simplifies calculation significantly; it is also described in
6) fnorm = 1 is defined as the frequency at which the [8] and [9], but for the purpose of this paper, it has been
conductor diameter is equal to the skin depth. summarized and placed in Appendix A.
OF SINGLE ROUNDWIRE
111. AC RESISTANCE V. ONE-DIMENSIONAL
ANALYSIS
USINGORTHOGONALITY
APPROACH
A single round wire, far removed from the retum conductor,
will only be subjected to skin effect. The exact analytical References [ 11 and [31 derived identical expressions for the
solution is readily found in the literature [7]: ac resistance of the with layer (see Fig. 2). Rewriting the
expression in terms of the notation adopted in this paper,
+
where
d
R,, = Rd,< (2rn
[
- (4m2 - 4m)
-
sirili 2< sin 2(
2rn + 1)
cosh 2[ - COS 2[
<
cos sirih sin [cosh + <
I
(3)
y=- cosh 2 [ - cos 2[
6Jz
Upon substitution, identities (B2) and (B3) in the above
and
expression, the following equation is obtained:
6 = skindepth.
+ sin E + ( ~ r r c
If the round conductor is replaced with a square-shaped con-
ductor of equal cross-sectional area, the skin effect resistance
sirih
- 112
sirih
cos11
E
(
- sin (
+ cos ( I
(4)
.
1 7
FERREIRA: IMPROVED ANALYTICAL MODELING OF CONDUCTIVE LOSSES 129
VI. AC RESISTANCE
OF ROUNDWIRE WINDINGS
The orthogonality principle makes theoretically more accu-
rate prediction of the ac resistance in multilayer round wire
windings possible. The assumption is made that the applied
field due to proximity effect is uniform, in which case skin
effect and proximity effect are orthogonal as described in
Appendix A, and a similar expression to (4) can be obtained
by applying skin effect resistance [(l) and proximity effect,
factor G (A8)], and the expression for the ac resistance of the
mth layer becomes
ber y bei' y - bei y ber' y
= Rdc - - 27r(2m - 112
+
berl2 y beil2 y
+
ber2 y ber' y bei2 y bei' y
+
ber2 y bei2 y
(5)
ratio Rac/Rdchas been plotted in Fig. 5. Note how the Fig. 5. Comparison between the exact cylindncal solution (0trace) and the
prediction by the square conductor representation is too low. square conductor, one-dimensional representation (+ trace) of the ac resistance
in two different layers of a multilayer winding.
In fact, at fnorm = 10, the prediction error is already -30%
for m = 1 and -47% for m = 4. of each layer is reduced by the factor 7 and the magnetic field
must be compensated by same factor, as is described in point
VII. GEOMETRICAL DEPENDENCY
OF SKIN DEPTH 5) in the Notation section. Equation (4) then becomes:
Dowel1 [2] introduced a skin depth that is dependent on the
packing factor 7 (defined in Fig. 3), which was also adopted
by subsequent papers [4], [5]. The geometrical skin depth is
defined as follows: (7)
1
(6) where
F .
where 0 < 7 5 1.
Such an adaptation was necessary because 7 involves a
second dimension within a strictly one-dimensional solution. The factor q2 in the above equation is valid and makes
In effect, the gaps between the square conductor are filled up physical sense. Skin depth, on the other hand, is a physical
and the conductivity is adjusted to create infinitely wide foil material constant and cannot be dependent on geometry.
conductors. Furthermore, the average current along the width Proximity effect is caused by eddy currents induced by an
130 IEEE TRANSACTIONS ON POWER ELECTRONICS, VOL. 9, NO. 1. JANUARY 1994
APPENDIXA
ORTHOGONALITY IN THE POWER
Rac INTEGRAL OF EDDYCURRENT LOSSES
Rdc The current flow inside a conductor lead is taken to be in
the z direction and the density distribution is only a function
of the z,y coordinates.
J ( z ,y, t ) = J ( z , y) cos wt (41)
where J is the current density (phasor quantity) and w is the
repetition frequency of the current waveform.
1 The power dissipation per unit length (Pu)of the conductor
ai f m is, by definition,
Fig. 6. Ratio R a c / R d ,for true skin depth (0trace) and geometrical skin
depth (+ trace) when m = 4 and 11 = 0.6.
by using the geometrical skin depth is illustrated in Fig. 6. Since we have a sinusoidal waveform, (A2) can be simpli-
fied to
VIII. EXPERIMENTAL
MEASUREMENTS
An aspect common to the papers listed on the one-
P, = & s, J . JdA
dimensional analysis is the absence of proper experimental
Designating the skin effect and proximity effect current den-
verification. References [ l ] and [3] do not report any
sities J , and Jp. respectively, (A3) becomes
experimental work. Dowel1 [ 2 ] reports that the experimental
results have not been checked thoroughly and presents
no formal experimental results. Vandelac [5] mentions one
measurement. One reason for the lack of experimental suport
Provided the conductors have an axis of symmetry and the
is the technical difficulties involved with the measurement [ 101
applied field is uniform and parallel to the symmetry axis,
and the influence of secondary effects [ 111 such as interturn
an induced current distribution Jp displays reciprocal sym-
capacitance. Measurements were conducted by the author [8],
metry. The skin effect current distribution relative to the same
using the orthogonality approach, and good agreement was
symmetry axis is an even function, and under these conditions,
obtained between measured and predicted values for coils
using the orthogonality approach for round conductors.
IX. CONCLUSIONS
It has been shown that skin effect and proximity effect are
where Pusare the skin effect losses nd Pup are the proximity
orthogonal to each other for the one-dimensional Cartesian
effect losses.
solution for conductive losses in magnetic components, which
Skin effect losses per unit length is simply calculated using
means that the losses can be calculated separately and then
the following equation:
simply added together. This orthogonality concept can be
extended to a more exact method for calculation of the ac Pus = i R s k i n I 2 (A6)
resistance of round conductors.
It has been shown that this method of calculation is in- where I = peak value of current and &in is given by either
herently more accurate than a popular existing method using (1) or the rectangular approximation ( 2 ) .
an equivalent rectangular conductor and the one-dimensional The proximity effect losses for a round conductor can be
Cartesian coordinate system solution. Two areas of erroneous expressed per unit length as
prediction of the latter solution include the potential error due
pup= G H , ~ (A7)
to a geometrical dependency of the skin effect parameter,
and a prediction error which becomes prominent at frequencies where He = peak value of the external magnetic field caused
larger than fnorm = 3. On the positive side, it appears as if by currents in surrounding conductors.
1 1
The exact expression for G for a round conductor is as P. L. Dowell, Effects of eddy currents in transformer windings, Proc.
follows: IEE, vol. 113, pp. 1387-1394, Aug. 1966.
M. P. Perry, Multiple layer series connected winding design for
Gz-
-21ry ber2 y ber y + be22 y ber y . (A8)
minimum losses, IEEE Trans. Power App. Syst., vol. PAS-98, pp.
0 ber2 y + bei2 y 116-123, Jan./Feb. 1979.
B. Carsten, High frequency conductor losses in switch mode magnet-
ics, in PCI Proc., Munich, Germany, 1986, pp. 161-182.
The expression for G for the equivalent rectangular conductor J. P. Vandelac and P. D. Ziogas, A novel approach for minimizing high-
presentation is given by frequency transformer copper losses, IEEE Trans. Power Electron., vol.
3, pp. 266-276, July 1988.
\/r A. M. Urling, V. A. Niemela, G. R. Skutt, and T. G. Wilson, Char-
Gr-2 dE s i n h t - s i n (
acterizing high frequency effects in transformer windings-a guide to
several significant articles, in Conf. Rec. 1989 PESC, pp. 373-385.
0 cosh< +cos< R. L. Stoll, The Analysis of Eddy Currents. Oxford: Clarendon Press,
1974.
APPENDIXB J. A. Ferreira, Electromagnetic Modeling of Power Electronic Convert-
ers. Boston/Dordrecht/London: Kluwer Academic, 1989.
HYPERBOLICAL/TRIGONOMETRICAL
IDENTITIES J. A. Ferreira and J. D. van Wyk, A new approach to analyze conduction
losses in high frequency magnetic components, Trans. SAIEE, vol. 80,
The eddy current equations contain hyperbolical functions no. 1, pp. 6 1 4 7 , 1989.
of a complex variable cr of which the real and imaginary parts V. A. Niemela, G. R. Skunt, A. Urlin, Y. N. Chang, T. G. Wilson, H.
are equal: A. Owen, and R. C. Wong, Calculating the short-circuit impedance
of a multiwinding transformer from its geometry, in Con$ Rec. 1989
PESC, pp. 607417.
a = a+ja. 031) J. A. Ferreira and J. D. van Wyk, Experimental evaluation of losses
in magnetic components for power converters, IEEE Trans. Ind. Appl.,
The following two mathematical identities arise from the vol. 27, pp. 335-339, Mar./Apr. 1991
solution of the hyperbolic functions:
sinh 2a
cosh 2a
+ sin 2a
- cos 2a
=-[ +
1 sinh a sin a
2 cosh a - cos a
sinh a - sin a
cosh a cos a+
Jan A. Ferreira (M88) was bom in Pretoria, South
Africa, in 1958. He received the B.Eng., M.Eng.,
sinh 2a + sin 2a - sinh a - sin a and D.Eng. degrees in electrical engineering from
cosh 2a - cos 2a cosh a + cos a the Rand Afrikaans University, Johannesburg, South
Africa, in 1980, 1982, and 1988, respectively.
COS a sinh a + cosh a sin a) In 1981 he worked at the Institute of Power Elec-
+