Cálculo de las

Pérdidas Adicionales

en

Bobinas en Folio

Ing. Álvaro Portillo

Junio 2010

1
 Bobinas en Folio
Pérdidas Adicionales debidas al
Campo Magnético de Dispersión Radial
Este cálculo lo realizaremos basados en la Referencia:

Prof.Dr. Janusz Turoswki: “Additional losses in foil and bar wound transformers”
IEEE PES Winter Meeting and Symposium, New York, January 25-30, 1976,
Paper Nº A-76-151-1

a1 + a2 + δ
BMAX = µO H MAX BO = µO H O kR = 1 −
πL

→ → NI
L H MAX = 2
∫ H × dP = 2 NI
C AX
→ H MAX
kR
= 2 NI →
L
kR

→ →

∫ H × dP = 2 NI
C RD
→ H MAX L + 2 a2 H O = 2 NI

2 a2 H O = 2 NI − H MAX L = 2 NI − 2 NI k R

2 (1 − k R ) NI
2 a2 H O = 2 (1 − k R ) NI → HO =
2 a2

2
 HO =
2 NI
(1 − k R ) = 2 NI a1 + a2 + δ = 2 NI a1 + a2 + δ
2 a2 2 a2 πL L 2 π a2

2 π a2 2 NI
M= → HO =
a1 + a2 + δ ML

1 H MAX
M=
kR H O

Para dimensiones típicas M resulta comprendido entre 2 y 3.

Basados en el Método de las Imágenes calcularemos la penetración axial del

campo magnético de dispersión radial H O en la bobina de lámina suponiendo
que la bobina es una pared indefinida de espesor h , (indefinida en el sentido
radial x e indefinida en el sentido longitudinal z ).

→ →
→
∂B → → →
∂H
Ecuaciones de Maxwell: ∇∧E + =0 B = µO H ∇ ∧ E + µO =0
∂t ∂t
→ → → → → →
∇∧H = J J =σ E ∇∧H =σ E

→ → → →
Solución del Tipo: H = H ( y ) e jω t i E = E ( y ) e jω t k

h  h
Condiciones de Borde: H (y) = −HO y≥+ → H  +  = −HO
2  2
h  h
H ( y ) = + HO y≤− → H  −  = + HO
2  2

3
 → → →
i j k
→
∂ ∂ ∂ dE ( y ) jω t →
∇∧E = = e i
∂x ∂y ∂z dy
0 0 E ( y ) e jω t

→ → →
i j k
→
∂ ∂ ∂ dH ( y ) jω t →
∇∧H = =− e k
∂x ∂y ∂z dy
H ( y ) e jω t 0 0

→
∂H →
= jω H ( y ) e j ω t i
∂t

→
→ ∂H dE ( y ) jω t → →
∇ ∧ E + µO =0 → e i + jω µO H ( y ) e jω t i = 0
∂t dy

dE ( y )
+ jω µO H ( y ) = 0
dy

→ → dH ( y ) jω t → → dH ( y )
∇∧ H =σ E → − e k = σ E ( y ) e jω t k → + σ E(y) = 0
dy dy

dH ( y ) 1 dH ( y ) dE ( y ) 1 d 2H (y)
+ σ E( y ) = 0 → E( y ) = − → =−
dy σ dy dy σ dy 2

dE ( y ) 1 d 2H (y)
+ jω µ O H ( y ) = 0 → − + jω µO H ( y ) = 0
dy σ dy 2

d 2H (y)
− jω µO σ H ( y ) = 0
dy 2

k 2 = jω µO σ

ω µO σ ω µO σ 1
k= jω µO σ = j ω µO σ = (1 + j ) α= δ=
2 2 α

k = (1 + j ) α

Solución del tipo: H ( y ) = C1 e + k y + C2 e − k y

4
Con las condiciones de borde determinamos las constantes de integración C1 y
C2 :
h h
 h +k −k
H  +  = C1 e 2 + C2 e 2 = − H O
 2

h h
 h −k +k
H  −  = C1 e 2 + C2 e 2 = + H O
 2

h h h h
+k −k +k −k
e +e
2 2
e +e 2 2
C1 = − H O C2 = H O
e − e−k h
+k h
e − e− k h
+k h

h h h h
+k −k +k −k
e 2 + e 2 +k y e 2 + e 2 −k y
H (x ) = − H O + k h −k h
e + HO +k h e
e −e e − e− k h

h h
+k −k
e 2 + e 2 +k y
H (x ) = − H O + k h
e − e− k h
e − e−k y ( )

 + k 2h −k   + k
h h
−k 
h
e +k h
−e −k h

= e 2 
− e  e 2
+ e 2 
  

e + k y − e− k y
H (x ) = − H O h h
+k −k
e 2
−e 2

→ →
H = H (x ) e jω t j

→ e+ k y − e− k y → → sinh (k y ) jω t →
H = −H O e jω t j → H = HO e j
+k
h
−k
h
 h
e 2
−e 2 sinh  k 
 2

1 dH ( y ) k e + k y + e− k y
E( y ) = − → E (x ) = H O
σ dy σ +2 k
h
−2 k
h
e 2
−e 2

→ →
E = E ( x ) e jω t k

→
k e+ k y + e−k y →
E = HO e jω t k
σ +2 k
h
−2 k
h
e 2
−e 2

5
 → →
J =σ E

→ e+ k y + e− k y → → cosh (k y ) jω t →
J = k HO e jω t k → J = k HO e k
+k
h
−k
h
 h
e 2
−e 2 sinh  k 
 2

Simplificaciones:
h h
k >> 1 → 2α >> 1 → h >> 2 δ
2 2

h h h
+k −k +k
e 2
−e 2
≈e 2

e+ k y + e−k y
h
(e )
→ → −k →
J = k HO h h
e jω t k ≈ k H O e 2 +k y
+ e − k y e jω t k
+k −k
e 2
−e 2

h
(e )
→ −k →
J ≈ k HO e 2 +k y
+ e− k y e jω t k

→  − k  h − y  −k + y  
h 
→
J ≈ k H O  e  2  + e  2   e jω t k
h h
  − ≤ y≤+
  2 2

Esta expresión coincide con las fórmula 11 del Paper de Turowski

h 
→ −k  − y  →
J ≈ k HO e 2 
e jω t k h
0≤ y≤+
2

π
1+ j 2 HO BO
k = (1 + j )α =
j
= e 4
J1 = =
δ δ δ µO δ

h  π
→ −k  − y  →
J ≈ 2 J1 e 2 
j
e jω t k h
e 4
0≤ y≤+
2

Esta expresión coincide con las fórmulas 12 y 13 del Paper de Turowski

→ π h 
→ π (1+ j )  h 
→
2 j −k  − y  2 HO j −  − y
jω t
J≈ e 4
HO e 2 
e k= e e 4 δ 2 
e jω t k
δ δ

 h 
  −y
π 2 
h 
 −y
h 
 − y
h 
 −y j  − 
π 2  2  2  4 δ
→ − −j → −   →
HO j HO
J≈ 2 e 4e δ
e δ
e jω t k = 2 e δ
e  
e jω t k
δ δ

6
 h    h   h  
→
 −y
2   π  − y 
π
 − y  
J≈ 2
BO
e
−
δ 
cos −  2   + j sin  −
2   e jω t →
k
µO δ  4 δ  4 δ 
    
    

Esta es la fórmula 4.111 de la página 154 del libro de Kulkarni

Tomando la parte real obtenemos (resultan corrientes en cuadratura):

e jω t = cos ω t + j sin ω t

h    h   h  
 −y
2    π  − y    − y  
→
J≈ 2
BO
e
−
δ cos −  2   cos ω t − sin  π −  2   sin ω t  →
k
µO δ  4 δ  4 δ  
     
     
→
Operando en J :

h1 y
→ −  − 
δ2 h  h1 y π   h  1 y  π   jω t →
J ≈ 2 J1 e cos
    −  − 
 − j sin   −  −  e k
 δ  2 h  4   δ  2 h  4 

Tendremos además la corriente de carga:

→ →
J L = 2 J O e jω t k

La corriente total será:

h1 y
→
jω t
→ −  − 
δ 2 h  h1 y π   h  1 y  π   jω t →
J TOT = 2 J O e k + 2 J1 e cos  −  −  − j sin   −  −  e k
 δ  2 h  4   δ  2 h  4 

→  h 1 y 
−  − 
δ2 h  h1 y π   h  1 y  π   jω t →
JTOT = 2  J O + J1 e cos  −  −  − j sin   −  −   e k
  δ  2 h  4   δ  2 h  4  

Esta expresión coincide con la fórmulas 16, 17 y 18 del Paper de Turowski

Tomando la parte real obtenemos:

e jω t = cos ω t + j sin ω t

→  h 1 y 
−  − 
−e δ  2 h   h  1 y  π 
h 1 y 
−  − 
−e δ  2 h   h 1 y π   →
J TOT = 2  J O + J 1 e cos  −  −  cos ω t + J1 e sin   −  −  sin ω t  k
  δ  2 h  4  δ 2 h  4  

Esta expresión coincide con las fórmulas 17 y 18 del Paper de Turowski

7
 → →
JTOT = 2 JTOT e jω t k

h 1 y 
−  − 
δ2 h  h1 y π   h  1 y  π 
JTOT = J O + J1 e cos  −  −  − j sin   −  − 
 δ  2 h  4   δ  2 h  4 

Calcularemos ahora la potencia disipada.

1 ∗ W 
Considerando valores eficaces será: pV = J TOT × J TOT  3
σ m 

h 1 y   h 1 y  π 
−  −  − j   − − 
δ2 h δ  2 h  4
J TOT = J O + J1 e e 

h1 y
Z=  − 
δ 2h

 π  π
− jz−  + j  z− 
J TOT = J O + J1 e− Z e  4 ∗
J TOT = J O + J1 e − Z e  4

∗
  π
− j z−   
 π
+ j z−  
J TOT × JTOT =  J O + J1 e − Z e  4    J O + J1 e − Z e  4  
   

∗
 − j  z − π4 
−Z
 π
+ jz− 
J TOT × J = JO + J O J1 e e + e  4   + J1 e − 2 Z
2   2
TOT
 

∗  π
J TOT × JTOT = J O + 2 J O J1 e − Z cos z −  + J1 e − 2 Z
2 2

 4

 π 2
cos z −  = (cos z + sin z )
 4  2

∗
= J O + 2 J O J1 e − Z (cos z + sin z ) + J1 e −2 Z
2 2
J TOT × JTOT

h h
a 2 l 2
1 2 2al
∫∫∫ J ∫ ∫∫ J ∫J
∗ ∗ ∗
P= × J TOT dV = × J TOT dx dy dz = × J TOT dy
σ σ σ
TOT TOT TOT
V 0 0 0 0

a = a2 − a ISO = N eFOLIO
h

∫ [J ]
2
2al
P= + 2 J O J1 e − Z (cos z + sin z ) + J1 e− 2 Z dy
2 2

σ
O
0

8
 h1 y dy
Z=  −  dz = − dy = −δ dz
δ 2 h δ
h h
y: 0 → z: → 0
2 2δ

h
2δ

∫ [J ]
2al δ
P= + 2 J O J1 e − Z (cos z + sin z ) + J1 e− 2 Z dz
2 2

σ
O
0

h h
2δ 2δ
al h 2 2 alδ 2alδ
∫ e (cos z + sin z ) dz + J ∫e
−Z −2 Z
P = JO + J O J1
2 2
dz
σ σ σ
1
0 0

h
2δ h h

∫ e (cos z + sin z ) dz = [− e ]
− h
−Z −Z 2δ 2δ
cos z =1− e cos
2δ
0
0

h
h
2δ
 2δ 1  − 
h
 1
∫e
−2 Z
dz = − e− 2 Z  = 1 − e δ 
0  2 0 2 

2 2 a l δ  h 
h
al h −
2 alδ  − 
h
P = JO
2
+ J O J1 1 − e 2 δ cos + J1 1 − e δ 
σ σ  2δ  σ  
  

a l h  J1 δ  h  J1 δ  − 
h 2 h
δ 
−
2 2δ
P = JO 1 + 2 2 1 − e cos + 1 − e 
σ  J O h  2 δ  J O 2 h  


a l h  J1 δ   h  −  
h
 h
1 − e δ  
− J1
2δ
P = JO 1 + 2  2 1 − e cos +
2

σ  J O h   2 δ  2 JO  
    

a l h  J1 δ  J1  
h >> δ → P ≈ JO 1 + 2 2 +
2

σ  JO h  2 JO  

Esta expresión coincide con la fórmula 20 del Paper de Turowski

HO 2 NI NI
J1 = HO = JO =
δ ML ah

J1 H O a h 2 NI 1 a h 2a h
= = =
JO δ NI M L δ NI δ M L

9
 PADIC RAD J1 δ  J1  2a h δ  1 2a h
k ADIC RAD = = 2 2 + = 2 2 + 
RI 2
JO h  2 JO  δM L h  2 δ M L

PADIC RAD 2a  ah 
k ADIC RAD = 2
= 2 + δ M L 
RI ML  

Finalmente resulta la “Fórmula de Turoswki” :

PADIC RAD 4a  ah 
k ADIC RAD = 2
= 1 + 2 δ M L 
RI ML  

Calcularemos la profundidad de penetración δ para cobre y aluminio:

ω µOσ ω µO 2ρ
α= = → δ=
2 2ρ ω µO

Hy
ω = 2π f µO = 4 π ×10 −7
m

235 + t
Cobre @ t (º C ) : ρ (Ωm ) = 0.210 × 10− 7
310

225 + t
Aluminio @ t (º C ) : ρ (Ωm ) = 0.344 × 10− 7
300

50 Hz 60 Hz
δ (mm)
75ºC 85ºC 75ºC 85ºC

Cobre 10.3 10.5 9.4 9.6

Aluminio 13.2 13.4 12.1 12.3

Para temperaturas comprendidas entre 75ºC y 85ºC será:

50 50
Cobre: δ = 10.4 Aluminio: δ = 13.3
f f

10
• Fórmula DTDS - PAUWELS:

4a  ah 
k ADIC RAD = 1 + 2 δ M L 
ML  

Correciones:
• L = h = Altura de la Lámina de BT
• k = 0.6 para Cobre
• k = 0.9 para Aluminio

4a  a 
k ADIC RAD = 1 + 2 δ M  k
Mh  

• Fórmula ABB:

4a  ah 
k ADIC RAD = 1 + 2 δ M L 
ML  

Correciones:
• M → 2M
• L = Altura de la Ventana del Núcleo
• h = Altura de la Lámina de BT
• h2 = Altura de la Bobina de AT
2
h  h 
• k = 36  2  − 62.9  2  + 27.9
h h
h = h2 → k = 1

4a  ah 
k ADIC RAD = 1 + k
2 M L  2 2δ M L 

11
“Transformer Engineering – Design and Practice”
S.V.Kulkarni – S.A.Kharparde
Marcel Dekker Inc. – 2004

4.5.4 Eddy loss in foil windings

In small transformers, foil windings (made up of thin sheets of copper or

aluminum) are quite popular because of the simplicity obtained in the winding
operations. The metal foil and the insulation layer can be wound simultaneously
on a special machine and the whole process can be easily mechanized.

In foil windings, eddy loss due to axial leakage field is insignificant because of
very small thickness of the foil. On the contrary, the radial field results into
higher eddy loss at the ends of the foil windings. The eddy loss in a foil winding
can be evaluated by analytical or numerical methods.

The current density has been obtained as a solution of integral equation

(Fredholm type) for a two winding transformer in [20]. For specific transformer
dimensions given in the paper, the coefficient of additional loss is 1.046, i.e., the
eddy loss is 4.6% of the DC I2R loss.

In another approach [21], a boundary-value field problem is solved for magnetic

vector potential in cylindrical coordinate system using modified Bessel and
Struve functions. For symmetrically placed LV (foil) and HV windings, the
additional loss factor reported is 5.8%. For an asymmetrical arrangement of
windings this loss increases.

In [22], the foil winding is assumed as a vertical section of an infinitely wide and
deep conducting plate, which is assumed symmetrically penetrated on both
sides by plane electromagnetic waves.

The geometry is given in figure 4.10, where h is the height of the foil winding
and BX denotes the value of flux density at winding ends.

The induced eddy current density (with the vertical dimensions specified with
respect to the middle of the winding height) is [22]:

h    h   h  
 −x 
  π  − x    − x  
−
  + j sin π −  2
2 
cos  −  2  
BO (4.111)
Je = e δ
µO δ  4 δ  4 δ 
    
    

12
The eddy loss in terms of the peak value of current density is given as

1
∫
2
Pe = J e dV (4.112)
2σ V

It is clear from equations 4.111 and 4.112 that

h 
 −x
2 
2 −2
Pe ∝ J e ∝ e δ
(4.113)

Hence, the maximum value of eddy loss occurs at y=h/2 (at two ends of the
winding) since at this height the exponential term has the maximum value of 1,
whereas its value is just 0.0067 at y=(h/2)-2.5×δ, which means that more than
99% of the induced eddy current loss occurs in just 2.5×δ depth from the
winding ends.

For an aluminum foil winding, whose skin depth is 13.2 mm at 50 Hz, almost all
the eddy loss is concentrated in 33 mm from the winding ends. The foil winding
eddy current density distribution calculated by equation 4.111 for a typical
transformer is shown in figure 4.11.

Thus, the current density at the ends can be about 1.5 to 2 times the uniform
current density, resulting into local heating of 2.25 to 4 times that in the middle
portion of the winding. Hence, the temperature rise at the foil winding ende
should be carefully assessed.

Usually, there is no temperature rise problem in a foil winding since the thermal
conductivity of aluminum/copper is quite good, and the winding edges are well
exposed to the cooling medium. If a transformer with foil winding is supplying a
power electronic load, there is increase in the heating effect at winding ends on
account of harmonics [23].

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With the development in computational facilities, the numerical tools such as
FEM can easily analyze the foil winding eddy problem without any
simplifications done in analytical formulations. It is actually a three-dimensional
problem. The losses in a foil winding calculated in the core-window cross
section are lower than that calculated in the region outside the window. The
radial flux at winding ends is usually more in the region outside the window, and
hence the additional loss factor may be of the order of 10 to 15%. The position
of foil winding affects its eddy loss significantly. If the foil winding is the outer
winding, the radial flux density at ends reduces resulting in reduction of eddy
loss [24].

References:

20. N.Mullineux, J.R.Reed, and I.J.Whyte: “Current distribution in sheet and foil
wound transformers”, Proceedings IEE, Vol. 116, No. 1, January 1969, pp. 127–
129.

21. M.M.El-Missiry: “Current distribution and leakage impedance of various

types of foil-wound transformers”, Proceedings IEE, Vol. 125, No. 10, October
1978, pp. 987–992.

22. J.Turowski: “Additional losses in foil and bar wound transformers”, IEEE
PES Winter Meeting and Symposium, New York, January 25–30, 1976, Paper
No. A-76–151–1.

23. A.Genon, W.Legros, J.P.Adriaens and A.Nicolet: “Computation of extra

joule losses in power transformers”, ICEM 88, pp. 577–581.

24. B.S.Ram: “Loss and current distribution in foil windings of transformers”,

Proceedings IEE—Generation, Transmission and Distribution, Vol. 145, No. 6,
November 1998, pp. 709–716.

14
“Advanced Calculations of Magnetic Leakage Fields in Transformers”
O.W. Andersen

2.2 Sheet winding transformer

When radial flux tries to penetrate a sheet winding, induced eddy currents will
be set up to prevent it, according to Lenz's law. As a result, flux lines will be
straightened out through the winding and will be almost purely axial, except
at the very ends. This is shown in Fig.2 in a sheet winding with six turns.

Fig.2. Sheet winding transformer

Induced currents are phase shifted with respect to the main current in the
winding, so that vector potentials must be calculated as complex numbers.

Current densities will usually be very high at the winding ends, often several
times the average. However, this is concentrated in a small volume, and
losses and temperature rise are usually tolerable.

Current density distribution can be improved by making the low voltage sheet
winding slightly longer than the high voltage wire winding in a transformer
such as the one in Fig.2.

Current density distribution is calculated in each turn. The distribution is

shown in Fig.3 for the inner turn of the sheet winding in Fig.2 from the radial
centerline to the end of the winding. Each vertical bar represents the current
density calculated in a finite element mesh. The horizontal dashed line
represents the current density for a uniform distribution.

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Fig.3. Current density distribution, inner turn

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