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11/22/2016 Theory

CoilResistanceFormula
Itisquitestraightforwardtoderiveanequationwhichwillgiveyouthecoil
resistancetoanaccuracyofbetterthan+/10%.Thisequationusesthemain
parametersofouterradius,RO,innerradius,RI,lengthLandwirediameter
asillustratedinfig1below.

Fig1Coilparameters

Theamountofspacebetweenadjacentturnswilldependonhowneatlythe
coiliswound.Ifweconsiderthewiretobewoundneatlysothateachstrand
effectivelyoccupiesatotalcrosssectionalareaof thenratiobetweenthe
effectiveoccupiedareaandtheactualcrosssectionalareaofthewireisgiven
below.

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11/22/2016 Theory



Eqn1

Thisisareasonableassumptionsinceeachlayerofthecoilliesataslight
helixangleoppositetotheprecedinglayersotheturnsdon'tfallintothegaps
inthelowerlayer.Howeverforthegeneralcasewewilladoptageneralratio,
F,andtermitthecoil'fillingfactor'.IwouldthinkthatinmostinstancesFwill
liearound /4(0.79).

Ifweassumethisratioholdsthroughoutthewholevolumeofthecoilwecan
expressthevolumeofcopperwire,Vc,intermsofthetotalvolume,VT,as
follows:




Eqn2

Nowthatwehaveanexpressionforthevolumeofwireinthecoilwecan
easilydeterminetheactuallengthofwire,Lw,asfollows:

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Eqn3

Nowthatwehaveanexpressionforthelengthofthewireweneedonemore
substitutiontoexpresstheresistanceintermsofthecoilparameters.Taking
eqn3andsubstitutingitintothestandardresistanceequationgivesusthe
desiredresult:


Eqn4

Sonowwehavethecoilresistance,RC ,expressedintermsofthewire
resistivity, ,thecoildimensions,andthewirediameter, .

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11/22/2016 Theory

Ifweassumeafillingfactorof /4thenthisreducesto:

Eqn5

Somethingwhichshouldbenotedisthattheresistancedependsonthe .
ThismeansthatRcchangesbyalargefactorforasmallchangein .Lets
lookatanexample:

Supposewehavetwocoils,AandB,withthefollowingdimensions,

Ro=20mm,RI=10mm,L=20mm, A=1mm, B=1.2mm.

Wewilluse =1.7E5 mm

WorkingouttheresistanceofeachcoilgivesCoilA=0.41 ,CoilB=0.20
.

Soyoucanseethatsmallchangesinthewirediameterwillhavealarge
effectontheresultingresistance.

Thisformulagivesfairlyaccurateresultsasshownbythecomparison
betweenthemeasuredandcalculatedtestcoilresistances.Thereareseveral
thingswhichcanthrowtheresultoffThewindingmaynotbeaperfecthollow
cylinderitmightbeslightlyovalinshapeThewirediametermaynotbe
theexactstateddiameter.Theresistivityofthewiremaynotbecorrectly
knownabestguesswouldbetousethevalueforpurecopper(assumingthe
wireiscopperofcourse)Finallythewindingsmaynotformsucharegular
patternandthiswillaltertheratioofwirevolume/totalvolume(fillingfactor).

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