In your Excel sheet, use a VLOOKUP table linked to an AWG or SWG Wire Gauge Chart to automatically suggest the correct wire size based on the calculated current. 5. Recommended Excel Sheet Layout
Go to Data > What-If Analysis > Goal Seek . Set cell "Regulation %" to value "3" by changing cell "Current Density". This automatically optimizes wire size.
Temperature rise ≈ (Total losses / Surface area)^0.8 Calculate copper loss = I²R (using winding resistances from mean length per turn). Add core loss (from manufacturer data sheet). Compare to allowed rise (e.g., 50°C).
An Excel-based tool handles designs up to ~10 kVA. For higher power (three-phase, high-frequency, or large industrial units), you’ll need finite element analysis (FEA) or specialized software like ANSYS Maxwell or PExprt.
TPV=14.44×f×Bmax×Ac×10-4cap T cap P cap V equals the fraction with numerator 1 and denominator 4.44 cross f cross cap B sub m a x end-sub cross cap A sub c cross 10 to the negative 4 power end-fraction : Frequency (e.g., Bmaxcap B sub m a x end-sub : Maximum flux density (typically Tesla for silicon steel). Accap A sub c : Core area in cm2c m squared =1 / (4.44 * f * Bmax * Ac * 0.0001) 3. Calculate Total Winding Turns Once you have the TPVcap T cap P cap V