Loss Optimization Approach in Flyback Transformer Windings

The paper gives a complete information about a novel approach to optimization of high frequency losses of flyback transformer windings. Optimization of the transformer’s topology is one of the challenges in flyback design. Selecting the wire thickness, type, and placement of the windings becomes an important criterion for efficient operation of the converter. The paper gives a detailed analysis of the losses in the flyback. Special attention is given to the eddy current losses calculation method and its verification. This method helps to estimate and optimize high-frequency copper losses, caused by the skin and proximity effect. The losses depend on the configuration of the winding layers of the magnetic component. Based on an analysis of the well-known approaches, described in the literature, a new analytical method for calculating eddy current losses in magnetic components with arbitrary currents is presented. An experiment was carried out to measure the losses in a real transformer. It helps to verify the obtained results. The losses obtained during calculations and the experimental data are shown in this paper.