window utitlization factor Ku

-----Tom_huang()
The window utilization factor is the ratio of the copper area to total window area of the transformer or inductor , Window utilization is influenced by 4 different factors: 1: wire insulation 2: wire lay(fill factor ) 3: bobbin area(or,when using a toroid,theclearance hole of passage of the shuttle) 4: insulation required for multilayer winding or between windings In the design of high-current or low-current transformers ,the ration of conductor area over total wire area can have a range from 0.941 for a number 10AWG to 0.673 for number 40AWG,depending on the wire size. The wire lay or fill factor can vary from 0.7 to 0.55 , depending on the winding technique,the winding techniqye can be defined on paper but will vary from one winder to another.the amount and the type of insulation are dependent on the voltage . The fraction Ku of the available core window space which will be occupied by the winding (copper) is calculated from area S1,S2,S3 and S4: Ku=S1*S2*S3*S4 When designing low-current transformer, it is advisable to reevaluate S1 because of the increased amount of insulation see Figure 1

S1 is the fill factor for the usable window area, It can be shown that for circular cross-section wire woundon a flat form the ration of wire area to the area required for the turns can never be greater than 0.91. Inpractice, the actual maximum value is dependent upon the tightness of winding ,variations in insulation thickness, and wire lay. Consequently, the fill factor is always less than the theoretical maximum. As a typical working value for copper wire with a heavy synthetic film insulation, a ratio of 0.6 may be safety used see Figure 2: S2=fill factor = 0.6

S2 defines how much of the available window space may actually be used for the winding. The winding area available to the designer depends on the bobbin configuration. A single bobbin design offers an effective area Wa between 0.835 to 0.929 while a two bobbin configuration offers an effective area Wa between 0.687 to 0.872. A good value to use for both configurations is 0.75. S3= Wa(bobbin) / Wa(core)=0.994/1.495=0.655

Its is important to remember that when designing magnetic components using ferrites such as RM,PQ, ETD,etcit is wise to reevaluate the window utilization factor Ku .The bobbins are designed to take this shrinkage into account so one bobbin fits all. This will impact the available window space snd S3 will have to re-evaluated downwards to about 0.6; see Figure 3. S4 defines how much of the usable window space is actually being used for insulation,If the transformer has multiple secondaries having significant of insulation, S4 should be reduced by 2.5% for each additional secondary winding because of the added space occupied by insulation ,in addition to a poorer space factor, A typical value for the copper fraction in the window area is about 0.4. For example: For AWG 20 wire , S1*S2*S3*S4=0.855*0.6*0.75*1.0=0.385,which is very close to 0.4.

use of the increased

r cross-section wire

never be greater than 0.91.

g ,variations in insulation typical working value for

the winding. The winding bin design offers an rs an effective area Wa

ferrites such as RM,PQ, are designed to take this dow space snd S3 will

sulation,If the transformer by 2.5% for each additional n to a poorer space factor, ample: For AWG 20 wire ,