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Magnetics designer

Pick an inductor or a flyback transformer, a core and the windings. The two table cores carry the values TDK publishes for them in its N87 ferrite [TDK Electronics, E 25/13/7 (EF 25)], [TDK Electronics, ETD 29/16/10]. For any other core, choose “Other core” and enter the values from its data sheet. The designer gives:

  • the fewest turns that keep the peak flux density within a limit, and the air gap that then gives the inductance;
  • for a table core, the gapped core sets its data sheet offers, with the turns each one needs;
  • the peak flux density, and the ac flux amplitude that the core loss depends on;
  • the window utilization, and each winding’s dc resistance and ac resistance factor at the switching frequency;
  • for a flyback, the leakage inductance of the winding arrangement.

Each result names its equation. The chart shows each winding’s ac resistance factor against frequency.

Enter the inductance and the peak and rms current of the winding. For a flyback these are the magnetizing inductance referred to the primary and the primary’s currents, and the secondary’s rms current is entered separately. The converter designer gives the inductance and the peak current. The ripple Δi\Delta i is half the peak-to-peak ripple, as everywhere on this site. BmaxB_\mathrm{max} is the largest flux density the design allows: below the material’s saturation flux density at the core’s highest temperature, with a margin [Erickson & Maksimović 2020, Ch. 11].

The flux density follows the current (peak flux density). Holding its peak at BmaxB_\mathrm{max} gives the fewest turns [Erickson & Maksimović 2020, Ch. 11]:

N=LIpkBmaxAeN = \frac{L I_\mathrm{pk}}{B_\mathrm{max} A_e}
NN
number of turns
AeA_e
effective core area
BmaxB_\mathrm{max}
largest flux density allowed
IpkI_\mathrm{pk}
peak current
LL
inductance
Fewest turns that keep the peak flux density at a limit✓ verified by 7 tests
Assumptions, convention and source
Assumptions
  • linear (unsaturated) magnetic material
  • flux density uniform over A_e
Notes
more turns lower the peak flux density at the same inductance and current, but lengthen the winding and raise its resistance
Source
Erickson & Maksimović 2020, Ch. 11 (Inductor Design); derived here
Derivation
step-by-step sympy derivation
Equation id
mag.N_Bmax · equations.yaml entry

The tool evaluates it at the core’s smallest cross-section AminA_\mathrm{min}, where the flux density is highest, and rounds up to whole turns. More turns lower the flux density further, but lengthen the winding and raise its resistance. Enter NN to use more.

With the turns fixed, the inductance sets the gap. The magnetic circuit of a gapped core (inductance factor of a gapped core), solved for the gap length, gives:

lg≈μ0AeN2L−leμil_g \approx \frac{\mu_0 A_e N^{2}}{L} - \frac{l_e}{\mu_i}
lgl_g
air-gap length
AeA_e
effective core area
LL
inductance
NN
number of turns
lel_e
effective magnetic path length
μi\mu_i
initial relative permeability
μ0\mu_0
permeability of free space
Air-gap length that gives an inductance with N turns✓ verified by 7 tests
Assumptions, convention and source
Assumptions
  • linear (unsaturated) magnetic material
  • no fringing flux at the gap
  • flux density uniform over A_e
Notes
a negative result means the ungapped core already gives less than this inductance with N turns: more turns are needed; fringing lets a real gap be somewhat longer than this estimate
Source
Erickson & Maksimović 2020, Ch. 11 (Inductor Design); derived here
Derivation
step-by-step sympy derivation
Equation id
mag.gap_length · equations.yaml entry

Here μi\mu_i is the effective permeability of the ungapped set. The tool takes it from the data sheet’s ALA_L of the ungapped set, through the same equation with no gap. A negative result means that even the ungapped core gives less than the inductance with these turns: add turns.

This estimate ignores fringing. Around the gap the flux spreads beyond the core’s area, so a real gap passes more flux than the estimate assumes, and it must be longer for the same inductance. A data sheet therefore gives the ALA_L of its gapped core sets, each a gapped core with an ungapped one [TDK Electronics, E 25/13/7 (EF 25)]. For a table core the tool lists these sets. For each it shows the turns that give the inductance, the inductance of those whole turns and the peak flux density at AminA_\mathrm{min}. The button in a row uses its turns. Use a set with a large gap, and compare its gap with the tool’s estimate for those turns: the real gap is clearly longer.

The peak flux density at AminA_\mathrm{min} is what must stay below saturation. The core loss depends on the swing instead. A ripple of ±Δi\pm\Delta i moves the flux density about its dc value by:

Bac=LΔiLNAeB_\mathrm{ac} = \frac{L \Delta i_L}{N A_e}
BacB_\mathrm{ac}
ac flux-density amplitude
AeA_e
effective core area
ΔiL\Delta i_L
inductor ripple, half peak-to-peak
LL
inductance
NN
number of turns
AC flux-density amplitude from the current ripple✓ verified by 7 tests
Assumptions, convention and source
Assumptions
  • linear (unsaturated) magnetic material
  • flux density uniform over A_e
Convention
ΔiL\Delta i_L is half the peak-to-peak ripple (Erickson), so BacB_\mathrm{ac} is half the peak-to-peak swing ΔB\Delta B: the amplitude that core-loss data take
Notes
the flux density follows the current, so the ripple alone sets its swing, the quantity core-loss data are given for; the dc current sets where the swing lies, and with it the margin to saturation (BpkB_\mathrm{pk})
Source
Erickson & Maksimović 2020, Ch. 10 (Basic Magnetics Theory); derived here
Derivation
step-by-step sympy derivation
Equation id
mag.B_ac · equations.yaml entry

This is the amplitude that core-loss data take (core loss per volume): read the loss per volume off the material’s loss curves at BacB_\mathrm{ac} and fsf_s, or use the loss budget. In a CCM inductor the ripple is a small part of the current, and so is BacB_\mathrm{ac} of BpkB_\mathrm{pk}. In a DCM flyback the current falls to zero every period, and the swing is the whole peak.

Each winding is round wire: ksk_s strands in parallel, each of bare diameter dwd_w and diameter dod_o over its insulation, wound in MℓM_\ell layers across the coil former’s winding breadth bwb_w. The copper of one turn, and the part of the window that all windings fill:

Aw=ksπdw24A_w = \frac{k_s \pi d_w^{2}}{4}
AwA_w
bare conductor area of one turn
dwd_w
bare wire diameter
ksk_s
strands in parallel
Copper area of one turn of round strands✓ verified by 8 tests
Assumptions, convention and source
Assumptions
  • definition
Notes
the bare diameter, without the insulation; wire tables give both
Source
National Bureau of Standards 1966
Equation id
wind.round_area · equations.yaml entry
Ku=NAwWAK_u = \frac{N A_w}{W_A}
KuK_u
window utilization
AwA_w
bare conductor area of one turn
NN
number of turns
WAW_A
winding window area
Window utilization of a winding✓ verified by 7 tests
Assumptions, convention and source
Assumptions
  • definition
Notes
insulation, the bobbin and the gaps between round wires leave only part of the window to copper; a design keeps K_u below what it can wind
Source
Erickson & Maksimović 2020, Ch. 11 (Inductor Design)
Equation id
wind.fill · equations.yaml entry

KuK_u must stay below what can actually be wound. Insulation, the coil former and the gaps between round wires take the rest [Erickson & Maksimović 2020, Ch. 11]. The tool warns above Ku,maxK_{u,\mathrm{max}}.

Copper’s resistivity rises with temperature. For annealed copper the tool uses the values of the NBS copper wire tables [National Bureau of Standards 1966]:

ρw=ρ20(1+α20(Tw−20))\rho_w = \rho_{20} \left(1 + \alpha_{20} \left(T_w - 20\right)\right)
ρw\rho_w
conductor resistivity
TwT_w
winding temperature
α20\alpha_{20}
temperature coefficient at 20 °C
ρ20\rho_{20}
resistivity at 20 °C
Resistivity of a conductor at its temperature✓ verified by 8 tests
Assumptions, convention and source
Assumptions
  • resistance linear in temperature near 20 °C
Notes
for annealed copper ρ20=1.7241×10−8 Ω m\rho_{20} = 1.7241 \times 10^{-8}\,\Omega\,\mathrm{m} and α20=0.00393\alpha_{20} = 0.00393 per kelvin; a winding at 100 °C has about 31 % more resistance than at 20 °C
Source
National Bureau of Standards 1966
Equation id
wind.rho_T · equations.yaml entry
Rdc=ρwNMLTAwR_\mathrm{dc} = \frac{\rho_w N \mathrm{MLT}}{A_w}
RdcR_\mathrm{dc}
winding dc resistance
AwA_w
bare conductor area of one turn
MLT\mathrm{MLT}
mean length per turn
NN
number of turns
ρw\rho_w
conductor resistivity
DC resistance of a winding✓ verified by 7 tests
Assumptions, convention and source
Assumptions
  • a dc current spread uniformly over the conductor's cross-section
Notes
the winding is a conductor N⋅MLTN \cdot \mathrm{MLT} long; the resistivity of copper rises with temperature
Source
Erickson & Maksimović 2020, Ch. 11 (Inductor Design); derived here
Derivation
step-by-step sympy derivation
Equation id
wind.dcr · equations.yaml entry

Irms2RdcI_\mathrm{rms}^2 R_\mathrm{dc} (conduction loss) is the loss the current would cause if it were dc. The ac part of the current adds to it, as the next section shows.

At high frequency the current crowds into a surface layer about a skin depth thick [Erickson & Maksimović 2020, Ch. 10]:

δ=ρwπμ0f\delta = \sqrt{\frac{\rho_w}{\pi \mu_0 f}}
δ\delta
skin depth
ff
frequency
ρw\rho_w
conductor resistivity
μ0\mu_0
permeability of free space
Skin depth of a conductor✓ verified by 8 tests
Assumptions, convention and source
Assumptions
  • a good conductor carrying a sinusoidal current (displacement current neglected)
Notes
the current density falls by a factor ee for every skin depth into the conductor; conductors much thicker than δ\delta carry the current in a surface layer
Source
Erickson & Maksimović 2020, Ch. 10 (Basic Magnetics Theory: eddy currents in winding conductors); derived here
Derivation
step-by-step sympy derivation
Equation id
wind.skin_depth · equations.yaml entry

In a winding of several layers, each layer also carries the field of the layers below it, which induces eddy currents in it: the proximity effect. Dowell’s analysis treats each layer as a foil [Dowell 1966]. For round wire, each strand becomes a square of the same area, and the layer becomes a foil of that thickness whose gaps lower its conductivity [Erickson & Maksimović 2020, Ch. 10]:

η=Nℓksπ4dwbw\eta = \frac{N_\ell k_s \sqrt{\frac{\pi}{4}} d_w}{b_w}
η\eta
porosity of a layer
NℓN_\ell
turns per layer
bwb_w
winding breadth
dwd_w
bare wire diameter
ksk_s
strands in parallel
Porosity of a layer of round conductors✓ verified by 8 tests
Assumptions, convention and source
Assumptions
  • each round conductor replaced by a square conductor of the same area, the layer by a foil of that thickness
Notes
a square of side π/4 dw\sqrt{\pi/4}\,d_w has the strand's area; a layer whose squares fill the whole breadth has porosity 1, and a value above 1 means the turns do not fit in the layer
Source
Dowell 1966; Erickson & Maksimović 2020, Ch. 10 (Basic Magnetics Theory: foil windings and layers)
Equation id
wind.porosity · equations.yaml entry
φ=ηπ4dwδ\varphi = \frac{\sqrt{\eta} \sqrt{\frac{\pi}{4}} d_w}{\delta}
φ\varphi
layer thickness over skin depth
dwd_w
bare wire diameter
δ\delta
skin depth
η\eta
porosity of a layer
Dowell's layer thickness for round conductors✓ verified by 8 tests
Assumptions, convention and source
Assumptions
  • each round conductor replaced by a square conductor of the same area, the layer by a foil of that thickness
Notes
the equivalent foil is π/4 dw\sqrt{\pi/4}\,d_w thick; its gaps lower its effective conductivity by the porosity, which enters as η\sqrt{\eta}
Source
Dowell 1966; Erickson & Maksimović 2020, Ch. 10 (Basic Magnetics Theory: foil windings and layers)
Equation id
wind.phi_round · equations.yaml entry
FR=φ(sinh⁡(2φ)+sin⁡(2φ)cosh⁡(2φ)−cos⁡(2φ)+2(Mℓ2−1)(sinh⁡(φ)−sin⁡(φ))3(cosh⁡(φ)+cos⁡(φ)))F_R = \varphi \left(\frac{\sinh{\left(2 \varphi \right)} + \sin{\left(2 \varphi \right)}}{\cosh{\left(2 \varphi \right)} - \cos{\left(2 \varphi \right)}} + \frac{2 \left(M_\ell^{2} - 1\right) \left(\sinh{\left(\varphi \right)} - \sin{\left(\varphi \right)}\right)}{3 \left(\cosh{\left(\varphi \right)} + \cos{\left(\varphi \right)}\right)}\right)
FRF_R
ac resistance factor
MℓM_\ell
layers from zero to peak MMF
φ\varphi
layer thickness over skin depth
AC resistance factor of a foil winding (Dowell)✓ verified by 9 tests
Assumptions, convention and source
Assumptions
  • foil layers spanning the winding breadth, a sinusoidal current, and a one-dimensional field in the window
Notes
the first term is the skin effect in each layer, the second the proximity effect of the layers' fields on each other, growing as Mℓ2M_\ell^2; with φ\varphi well below 1 the factor tends to 1
Source
Dowell 1966; Erickson & Maksimović 2020, Ch. 10 (Basic Magnetics Theory: eddy currents in winding conductors)
Equation id
wind.dowell · equations.yaml entry

FRF_R is the ratio of the ac resistance to RdcR_\mathrm{dc} at one frequency. Each harmonic of the current sees the factor at its own frequency, so the chart plots FRF_R against frequency, with fsf_s marked. With φ\varphi above 1, each added layer raises FRF_R steeply, as Mℓ2M_\ell^2. The remedies are fewer layers of thinner strands in parallel, or a foil.

In an inductor with a small ripple, the ac part of the current is small and FRF_R matters little: the table’s dc loss is then most of the copper loss. A flyback’s windings carry pulses, so much of each winding’s rms current is ac. Its harmonics see FRF_R at their frequencies, and the copper loss can be several times the dc loss.

The field between the windings stores energy that does not couple them: the leakage inductance. With the secondary wound over the primary (P-S):

Llk=μ0N2MLT(hp3+hg+hs3)bwL_\mathrm{lk} = \frac{\mu_0 N^{2} \mathrm{MLT} \left(\frac{h_p}{3} + h_g + \frac{h_s}{3}\right)}{b_w}
LlkL_\mathrm{lk}
leakage inductance (primary)
MLT\mathrm{MLT}
mean length per turn
NN
number of turns
bwb_w
winding breadth
hgh_g
spacing between the windings
hph_p
primary winding height
hsh_s
secondary winding height
μ0\mu_0
permeability of free space
Leakage inductance of a primary-secondary winding arrangement✓ verified by 7 tests
Assumptions, convention and source
Assumptions
  • one-dimensional field in the winding window: the MMF changes only across the layers, and the field runs along the winding breadth
Notes
referred to the primary; each winding counts with a third of its height and the spacing in full, and a broad, low window gives the least leakage
Source
Erickson & Maksimović 2020, Ch. 10 (Basic Magnetics Theory: leakage flux in windings, MMF diagrams); derived here
Derivation
step-by-step sympy derivation
Equation id
xfmr.leakage.ps · equations.yaml entry

Splitting the primary into two halves around the secondary (P-S-P) halves the peak magnetomotive force in the window, and the leakage falls to about a quarter [Erickson & Maksimović 2020, Ch. 10]:

Llk=μ0N2MLT(hp3+2hg+hs3)4bwL_\mathrm{lk} = \frac{\mu_0 N^{2} \mathrm{MLT} \left(\frac{h_p}{3} + 2 h_g + \frac{h_s}{3}\right)}{4 b_w}
LlkL_\mathrm{lk}
leakage inductance (primary)
MLT\mathrm{MLT}
mean length per turn
NN
number of turns
bwb_w
winding breadth
hgh_g
spacing between the windings
hph_p
primary winding height
hsh_s
secondary winding height
μ0\mu_0
permeability of free space
Leakage inductance with the primary split around the secondary (P-S-P)✓ verified by 7 tests
Assumptions, convention and source
Assumptions
  • one-dimensional field in the winding window: the MMF changes only across the layers, and the field runs along the winding breadth
Notes
splitting the primary halves the peak MMF, so the stored energy, and with it the leakage, falls to about a quarter
Source
Erickson & Maksimović 2020, Ch. 10 (Basic Magnetics Theory: interleaving the windings); derived here
Derivation
step-by-step sympy derivation
Equation id
xfmr.leakage.psp · equations.yaml entry

The tool takes a winding’s height as its layers times dod_o, and hgh_g as the insulation between two windings (for P-S-P, at each of the two interfaces). In a flyback the leakage energy goes to the clamp: take this inductance to the clamp check.

A buck inductor on the E 25/13/7 set:

Buck inductor example
SymbolValueHow it is obtained
LL inductance100 µHgiven
IL,pkI_{L,\mathrm{pk}} peak inductor current2.2 Agiven
IL,rmsI_{L,\mathrm{rms}} rms inductor current2 Agiven
ΔiL\Delta i_L inductor ripple, half peak-to-peak200 mAgiven
fsf_s switching frequency100 kHzgiven
BmaxB_\mathrm{max} largest flux density allowed300 mTgiven
TwT_w winding temperature100 °Cgiven
bwb_w winding breadth15 mmgiven
Ku,maxK_{u,\mathrm{max}} largest window utilization that can be wound0.4given
dwd_w bare wire diameter0.8 mmgiven
dod_o wire diameter over its insulation0.86 mmgiven
ksk_s strands in parallel1given
MℓM_\ell layers of the winding (Dowell's M)1given
AeA_e effective core area52.5 mm²TDK Electronics, E 25/13/7 (EF 25)
AminA_\mathrm{min} smallest cross-section of the core51.5 mm²TDK Electronics, E 25/13/7 (EF 25)
lel_e effective magnetic path length57.5 mmTDK Electronics, E 25/13/7 (EF 25)
AL0A_{L0} inductance factor of the ungapped set1.85 µHTDK Electronics, E 25/13/7 (EF 25)
WAW_A winding window area61 mm²TDK Electronics, E 25/13/7 (EF 25)
MLT\mathrm{MLT} mean length per turn50 mmTDK Electronics, E 25/13/7 (EF 25)
NminN_\mathrm{min} fewest turns for Bmax, at Amin14.24Fewest turns that keep the peak flux density at a limit
NN number of turns15rounded up
ALA_L inductance factor the design needs444.4 nHInductance from the inductance factor
μe\mu_e effective permeability of the ungapped set1612Inductance factor of a gapped core
lgl_g gap, without fringing0.1128 mmAir-gap length that gives an inductance with N turns
BpkB_\mathrm{pk} peak flux density (at Amin)284.8 mTPeak flux density from inductance and peak current
BacB_\mathrm{ac} ac flux-density amplitude25.4 mTAC flux-density amplitude from the current ripple
ρw\rho_w conductor resistivity (at Tw)22.66 nΩ·mResistivity of a conductor at its temperature
δ\delta skin depth (at fs)0.2396 mmSkin depth of a conductor
AwA_w bare conductor area of one turn0.5027 mm²Copper area of one turn of round strands
RdcR_\mathrm{dc} winding dc resistance33.81 mΩDC resistance of a winding
η\eta porosity of a layer0.709Porosity of a layer of round conductors
φ\varphi layer thickness over skin depth2.492Dowell's layer thickness for round conductors
FRF_R ac resistance factor (at fs)2.468AC resistance factor of a foil winding (Dowell)
PdcP_\mathrm{dc} loss at the dc resistance135.3 mWConduction loss in a resistance
KuK_u window utilization0.1236Window utilization of a winding

The fewest turns need a gap that no set of the data sheet has. In the tool’s table of gapped sets, the smallest gap needs as many turns but gives more inductance, so its peak flux density exceeds BmaxB_\mathrm{max}. The next set stays within it with a few more turns. One layer of this wire has an FRF_R well above 1 at the switching frequency, from the skin effect alone, but only the small ripple sees it.

A flyback transformer on the ETD 29/16/10 set, wound P-S. Its operating point is the converter designer’s flyback example at its lowest input voltage, with the inductance set to its ripple target:

Flyback transformer example
SymbolValueHow it is obtained
LML_M magnetizing inductance (primary)600 µHgiven
Ip,pkI_{p,\mathrm{pk}} peak primary current1.37 Agiven
Ip,rmsI_{p,\mathrm{rms}} rms primary current914 mAgiven
ΔiM\Delta i_M magnetizing ripple, half peak-to-peak174 mAgiven
fsf_s switching frequency100 kHzgiven
BmaxB_\mathrm{max} largest flux density allowed300 mTgiven
nn turns ratio, secondary/primary0.25given
Is,rmsI_{s,\mathrm{rms}} rms secondary current3.1 Agiven
TwT_w winding temperature100 °Cgiven
bwb_w winding breadth19 mmgiven
Ku,maxK_{u,\mathrm{max}} largest window utilization that can be wound0.4given
hgh_g spacing between the windings0.1 mmgiven
dwd_w bare wire diameter (primary)0.5 mmgiven
dod_o wire diameter over its insulation (primary)0.56 mmgiven
ksk_s strands in parallel (primary)1given
MℓM_\ell layers of the winding (Dowell's M) (primary)2given
dwd_w bare wire diameter (secondary)0.63 mmgiven
dod_o wire diameter over its insulation (secondary)0.69 mmgiven
ksk_s strands in parallel (secondary)2given
MℓM_\ell layers of the winding (Dowell's M) (secondary)1given
AeA_e effective core area76 mm²TDK Electronics, ETD 29/16/10
AminA_\mathrm{min} smallest cross-section of the core71 mm²TDK Electronics, ETD 29/16/10
lel_e effective magnetic path length70.4 mmTDK Electronics, ETD 29/16/10
AL0A_{L0} inductance factor of the ungapped set2.2 µHTDK Electronics, ETD 29/16/10
WAW_A winding window area97 mm²TDK Electronics, ETD 29/16/10
MLT\mathrm{MLT} mean length per turn52.8 mmTDK Electronics, ETD 29/16/10
NminN_\mathrm{min} fewest turns for Bmax, at Amin38.59Fewest turns that keep the peak flux density at a limit
NpN_p primary turns39rounded up
ALA_L inductance factor the design needs394.5 nHInductance from the inductance factor
μe\mu_e effective permeability of the ungapped set1622Inductance factor of a gapped core
lgl_g gap, without fringing0.1987 mmAir-gap length that gives an inductance with N turns
BpkB_\mathrm{pk} peak flux density (at Amin)296.9 mTPeak flux density from inductance and peak current
BacB_\mathrm{ac} ac flux-density amplitude35.22 mTAC flux-density amplitude from the current ripple
NsN_s secondary turns10n Np, rounded
ρw\rho_w conductor resistivity (at Tw)22.66 nΩ·mResistivity of a conductor at its temperature
δ\delta skin depth (at fs)0.2396 mmSkin depth of a conductor
AwA_w bare conductor area of one turn (primary)0.1963 mm²Copper area of one turn of round strands
RdcR_\mathrm{dc} winding dc resistance (primary)237.7 mΩDC resistance of a winding
η\eta porosity of a layer (primary)0.4664Porosity of a layer of round conductors
φ\varphi layer thickness over skin depth (primary)1.263Dowell's layer thickness for round conductors
FRF_R ac resistance factor (at fs) (primary)1.976AC resistance factor of a foil winding (Dowell)
PdcP_\mathrm{dc} loss at the dc resistance (primary)198.5 mWConduction loss in a resistance
AwA_w bare conductor area of one turn (secondary)0.6234 mm²Copper area of one turn of round strands
RdcR_\mathrm{dc} winding dc resistance (secondary)19.19 mΩDC resistance of a winding
η\eta porosity of a layer (secondary)0.5877Porosity of a layer of round conductors
φ\varphi layer thickness over skin depth (secondary)1.786Dowell's layer thickness for round conductors
FRF_R ac resistance factor (at fs) (secondary)1.657AC resistance factor of a foil winding (Dowell)
PdcP_\mathrm{dc} loss at the dc resistance (secondary)184.4 mWConduction loss in a resistance
KuK_u window utilization (both windings)0.1432Window utilization of a winding
LlkL_\mathrm{lk} leakage inductance (primary)3.736 µHLeakage inductance of a primary-secondary winding arrangement

Try P-S-P: the leakage falls to about a quarter. The flux swing is largest at the highest input voltage, where the duty ratio is lowest; enter that point’s ripple to read the core loss.

  • Round wire only. Foil and litz windings are not covered. Dowell’s factor assumes a one-dimensional field across the layers [Dowell 1966]. Near a gap the field is two-dimensional, and the factor does not describe the loss there.
  • Fringing. The gap estimate ignores it (see above). For a table core, use the data sheet’s gapped sets.
  • Flyback windings. The two windings conduct in turn, so their fields do not cancel as a transformer’s do. Each winding’s FRF_R is taken with its own layers, from zero field on one side. The eddy-current loss that a winding’s field induces in the idle winding is not modelled.
  • No core loss and no thermal model. The tool gives BacB_\mathrm{ac} for the material’s loss data, and takes the winding temperature as entered.
  • Core data. The ungapped set’s ALA_L has a wide tolerance, +30/−20 % [TDK Electronics, E 25/13/7 (EF 25)], and the gap estimate follows it.
The magnetics designer with the buck inductor example: the device, example and core buttons, the operating-point and core fields, the tables of turns, gap and flux density, of the winding and of the data sheet's gapped sets, and the chart of the ac resistance factor against frequency.
The magnetics designer with the buck inductor example.

The numbers in the examples, presets and exercises on this site are synthetic: round teaching values, not data from any real design.