A calculation method of winding loss of high frequency transformer based on finite element method

In this paper, a winding loss calculation method used in the field of converter transformers is introduced into the realm of high-frequency transformers for the first time. In addition, the impact of winding structure on the calculation accuracy of the method is considered for the first time. Comparing the calculation results of this method with those of the formula method, based on the results of finite element simulation. The feasibility of using this method to calculate the winding loss of a high-frequency transformer is verified. First, the winding loss of rectangular wire commonly used in small-capacity high-frequency transformers is analyzed. Based on the finite element simulation results, the accuracy of the hybrid method is compared with the formula calculation method to demonstrate the feasibility of the hybrid method. Then, using the same method, the accuracy of the hybrid method in calculating the winding loss of the circular wire, which is also used in small-capacity high-frequency transformers, is compared with the formula method. The maximum number of continuous winding layers has been modified, and the outcomes for various layers are being computed. Finally, the cross-transposition winding structure is also calculated, demonstrating that the hybrid method is not only applicable to wires of various shapes but also compatible with different winding structures. The results show that the hybrid method has good calculation accuracy and applicability. It can provide more precise calculation results for the winding loss of high-frequency transformers with various winding shapes.