EXPERIMENTAL AND NUMERICAL SIMULATION STUDY OF INDUCTOR FAULT BY INVESTIGATING WINDING CONTOUR

Multiple layer winding are typically with higher losses compare to singular layer.
Winding design and contour are important factors in inductors design with multiple
layer technique, since inductor design with multiple stacking are prone to proximity
effect. Thermal stress points in the inductor winding can cause insulation deterioration
and ageing effect, leading to winding faults. The contour design and its influence on
the winding fault of an inductor were investigated with the aim of selecting an
optimum winding contour design. In this dissertation, a winding fault model was
developed and behaviors of inductors with different winding contours are investigated
using the Finite Element Method (FEM) based on 2-Dimension model. The fault
model developed is able to calculate and determine the optimal combination of
parameters corresponding to various contour designs that would result in minimum
winding loss. Inductors with different winding contours have different thermal
envelopes and the geometry with the slowest thermal transition has fewer thermal
stress points potentially reducing winding fault at the conductor.