{"id":460999,"date":"2026-07-07T15:18:26","date_gmt":"2026-07-07T15:18:26","guid":{"rendered":"https:\/\/innovationspace.ansys.com\/forum\/forums\/topic\/unrealistically-big-solid-losses-in-transformer-design\/"},"modified":"2026-07-07T15:18:26","modified_gmt":"2026-07-07T15:18:26","slug":"unrealistically-big-solid-losses-in-transformer-design","status":"publish","type":"topic","link":"https:\/\/innovationspace.ansys.com\/forum\/forums\/topic\/unrealistically-big-solid-losses-in-transformer-design\/","title":{"rendered":"Unrealistically Big Solid Losses in Transformer Design"},"content":{"rendered":"<p>&lt;p&gt;Hello,&nbsp;&lt;br&gt;I&#8217;m simulating a 100 kHz transformer for a Dual Active Bridge (DAB) converter and I&#8217;m running into unrealistic winding losses.&lt;br&gt;In the first few timesteps, the solid loss spikes to around 50 MW, then settles down to a peak value of about 6 kW. Even this value seems far too high for a 25 kW transformer design.&lt;br&gt;&lt;br&gt;Here are the settings:&lt;br&gt;The transformer windings are supplied external by two rectangular voltage sources with rise and fall times of 1e-7 s. Primary Side Resistance 5.27e-3 Ohm and secondary side resistance 11.16 Ohm in the external circuit which should model the end winding.&lt;br&gt;2D Magnetic Transient Simulation XY&lt;br&gt;&lt;br&gt;Boundary Condition: VectorPotential: 0&lt;br&gt;&lt;br&gt;Excitation:&lt;br&gt;30 coils on primary side were assigned for primary winding and 14 coils on secondary side were assigned for secondary winding.&lt;br&gt;Number of parallel branches: 1&lt;br&gt;IsSolid: Solid&lt;br&gt;Set Eddy Effects: On for every turn&lt;br&gt;Set Core Loss: On for only core&lt;br&gt;&lt;br&gt;Mesh: 6400 elements (air 2277, core: 991, turns_pri: 32, turns_sec: 40)&lt;br&gt;&lt;br&gt;Solver:&lt;br&gt;Output per object core loss: yes&lt;br&gt;Output per object solid loss: yes&lt;br&gt;Time Decomposition Method Option: Periodic and Half-periodic&lt;br&gt;&lt;br&gt;Materials:&lt;br&gt;copper_pri: Composition: Litz Wire (Strand number: 223, Wire Dia: 0.1mm)&lt;br&gt;copper_sec: Composition: Litz Wire (Strand number: 450, Wire Dia: 0.1mm)&lt;br&gt;Ferrite Core: Core Loss: B &#8211; P Curve&lt;br&gt;&lt;br&gt;Values:&lt;br&gt;U_in = 800V&lt;br&gt;U_out = 350V&lt;br&gt;n1 = 30&lt;br&gt;n2 = 15&lt;br&gt;u = n1\/n2&lt;br&gt;r = u*U_out\/U_in&lt;br&gt;phi = pi\/3rad&lt;br&gt;f_sw = 100kHz&lt;br&gt;stopTime = 0.5*1\/f_sw&lt;br&gt;stepTime = 0.005*1\/f_sw&lt;br&gt;Model depth: 50 mm&lt;br&gt;&lt;br&gt;Thanks in advance for any input.&lt;\/p&gt;&lt;p&gt;Best Regards&lt;\/p&gt;&lt;p&gt;<img decoding=\"async\" src=\"https:\/\/innovationspace.ansys.com\/forum\/wp-content\/uploads\/sites\/2\/2026\/07\/07-07-2026-1783437464-Transformer.png\" alt=\"\" \/>&lt;\/p&gt;&lt;p&gt;<img decoding=\"async\" src=\"https:\/\/innovationspace.ansys.com\/forum\/wp-content\/uploads\/sites\/2\/2026\/07\/07-07-2026-1783437447-Solid Losses.png\" alt=\"\" \/>&lt;\/p&gt;&lt;p&gt;&nbsp;&lt;\/p&gt;<\/p>\n","protected":false},"template":"","class_list":["post-460999","topic","type-topic","status-publish","hentry","topic-tag-AnsysMaxwellelectronics-1","topic-tag-maxwell","topic-tag-transient"],"aioseo_notices":[],"acf":[],"custom_fields":[{"0":{"_bbp_forum_id":["27793"],"_bbp_topic_id":["460999"],"_bbp_subscription":["707274","602"],"_bbp_author_ip":["2a00:8a60:6103:13:862:2c44:b825:54fb"],"_bbp_last_reply_id":["461054"],"_bbp_last_active_id":["461054"],"_bbp_last_active_time":["2026-07-08 14:15:06"],"_bbp_reply_count":["1"],"_bbp_reply_count_hidden":["0"],"_bbp_voice_count":["2"],"_bbp_engagement":["707274","602"],"_btv_view_count":["28"],"_bbp_topic_status":["unanswered"]},"test":"mert-yazicirwth-aachen-de"}],"_links":{"self":[{"href":"https:\/\/innovationspace.ansys.com\/forum\/wp-json\/wp\/v2\/topics\/460999","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/innovationspace.ansys.com\/forum\/wp-json\/wp\/v2\/topics"}],"about":[{"href":"https:\/\/innovationspace.ansys.com\/forum\/wp-json\/wp\/v2\/types\/topic"}],"version-history":[{"count":0,"href":"https:\/\/innovationspace.ansys.com\/forum\/wp-json\/wp\/v2\/topics\/460999\/revisions"}],"wp:attachment":[{"href":"https:\/\/innovationspace.ansys.com\/forum\/wp-json\/wp\/v2\/media?parent=460999"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}