IEEE TRANSACTIONS ON MAGNETICS, VOL. 57, NO.

11, NOVEMBER 2021 8402207

Alternating-Current Copper Loss Reduction in a High-Frequency

Transformer for Railways Using a Magnetic Tape
Kazuhiro Shimura 1 , Kazuma Kubota1, Mitsuhide Sato 1 , Ttsutomu Mizuno1 ,
Masayuki Sakurada2, Takao Nebashi2 , and Norio Koike2
1
Faculty of Engineering, Shinshu University, Nagano 380-8553, Japan
2
Ichikawa Electric Company Ltd., Hamura 205-0023, Japan

The effective downsizing of power supply for railway by increasing the drive frequency is essential considering the mounting
space. However, an increase in the drive frequency increases the loss in switching and magnetic elements used for power supplies.
In this study, we focus on reduction of alternating current (ac) copper loss due to the skin and proximity effects by attaching a
magnetic material at appropriate positions on the outer circumference of the wire in high-frequency transformers for railway. In this
article, we propose a simple method of attaching magnetic materials to a winding in high-frequency transformers using a magnetic
tape. In the magnetic field simulation, we could reduce ac copper loss in the high-frequency transformer using magnetic tape. The
ac resistance at 16 kHz was reduced by 12.5% for the actual measurement using an impedance analyzer. The temperature rise at
the thermal saturation was reduced by 21.4% for the energization experiment with a current of 31.6 A and frequency of 16 kHz.
Analysis and actual measurements revealed that employing a magnetic tape in a high-frequency transformer can reduce ac copper
loss and heat generation.
Index Terms— Alternating current (AC) copper loss, magnetic tape, proximity effect, rectangular copper wire (RCW), skin effect,
transformer.

I. I NTRODUCTION However, these conventional techniques to reduce the skin

T HE demand for small, light, and high-efficiency magnetic
parts in transportation equipment, such as railways, auto-
mobiles, and aircrafts, is extremely high [1]–[4]. In railway
vehicles, transformers are used to convert the current and
voltage from overhead lines into the current and voltage
that can be handled by other electrical equipment. However,
miniaturization of large transformers driven at commercial
frequencies is indispensable. The size and weight of magnetic
components, such as transformers, can be effectively reduced
by increasing the drive frequency [5]–[8]. Recently, SiC-based
power devices have aided the increase of the drive frequency
of power supply systems for railway vehicles, which has
reduced the weight of transformers [9]. However, alternating-
current (ac) resistance due to the skin and proximity effects
increases with the increase in drive frequency. Therefore,
the loss of magnetic components at high-frequency needs to
be reduced [10], [11].
The skin effect of the winding can be effectively sup-
pressed by reducing the diameter of the round copper wire
to less than twice the skin depth and twisting the wire to
form a Litz wire [12]–[14]. Additionally, the proximity effect
can be suppressed using magnetic-plated wires with iron
thin films on copper wires and wires coated with magnetic
material using a spray [15], [16]. Furthermore, the use of
magnetically plated Litz wires for the simultaneous reduc-
tion of skin and proximity effects has been studied [17].
effect and proximity effect is limited to round wires and
cannot be applied to rectangular wires, which can effec-
tively utilize the winding area and are also effective in
downsizing [18], [19].
Rectangular wires are applied to various devices such
as motors, inductors, and transformers [20]–[22]. How-
ever, techniques for suppressing the skin effect in rectan-
gular wires have been studied, those for simultaneously
reducing the skin and proximity effects have not been
studied [23].
Therefore, magnetic flux path control has been pro-
posed as a technology to suppress the skin and proximity
effects [24]–[26]. The magnetic flux path control induces
magnetic flux by loading a magnetic material at an appropriate
position around a wire, enables simultaneous suppression of
both skin and proximity effects.
In this article, we propose the use of magnetic tape as a con-
venient means of loading magnetic material on a wire. Addi-
tionally, we propose application of magnetic flux path control
to a magnetic tape-wrapped rectangular copper wire (MRCW)
in which a magnetic tape is wound around a rectangular copper
wire (RCW).
We analyzed the magnetic field of a high-frequency trans-
former for railways using MRCW, the effect of reducing ac
resistance and suppressing heat generation.
The following are reported in this article:

Manuscript received July 8, 2021; revised August 5, 2021 and September 13, 1) ac copper loss reduction effect of a transformer using
2021; accepted September 13, 2021. Date of publication September 20, 2021; MRCW based on the magnetic field analysis;
date of current version October 18, 2021. Corresponding author: K. Shimura
(e-mail: 21hs204f@shinshu-u.ac.jp). 2) impedance characteristics of the transformer using
Digital Object Identifier 10.1109/TMAG.2021.3113498 MRCW; and
0018-9464 © 2021 IEEE. Personal use is permitted, but republication/redistribution requires IEEE permission.
See https://www.ieee.org/publications/rights/index.html for more information.

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8402207
TABLE I
S PECIFICATIONS OF A H IGH -F REQUENCY T RANSFORMER FOR R AILWAYS
Fig. 1. Equivalent circuit of the high-frequency transformer for railways.
3) heat-generation reduction effect of the transformer using
MRCW.
II. S PECIFICATIONS AND S TRUCTURES OF A
T RANSFORMER AND A M AGNETIC TAPE
A. Transformer Specifications and Structures
Table I shows the specifications of a high-frequency trans-
former for railways used as an auxiliary power supply during
rated driving.
The transformer has a drive frequency f = 16 kHz, primary
side voltage V p = 475 V, primary side current I p = 31.6 A,
secondary side voltage Vs = 650 V, secondary side current
Is = 23.1 A, and electric power Po = 15 kVA. The transformer
is used in auxiliary power supply units that supplies power
to the lighting and air conditioning in the cabin, and is
responsible for transforming and insulating the power.
Fig. 1 shows the equivalent circuit diagram of the high-
frequency transformer for railways. The primary winding of
the transformer consists of four eight-turn coils, two connected
in series and two in parallel. The secondary winding has
two 11-turn coils connected in series. Therefore, the ratio of
primary to secondary turns is 16:22.
Figs. 2 and 3 show the front view and A–A sectional view
of the high-frequency transformer for railways, respectively.
RCW with a width of 6.5 mm and a thickness of 2.0 mm was
used for both the primary and secondary windings. They were
alternated layer-by-layer to reduce the ac resistance [11], [27].
A nonmagnetic insulator is wrapped around a part of the
RCW using a magnetic tape in the MRCW. The magnetic
flux is interlinked with the RCW, and a spiral electric field
is generated by the interlinkage magnetic flux according to
Ampere’s law, which causes a bias in the current density of
the RCW and increases the ac copper loss due to proximity
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IEEE TRANSACTIONS ON MAGNETICS, VOL. 57, NO. 11, NOVEMBER 2021
Fig. 2. Front view of the high-frequency transformer for railways (unit: mm).
effect. The magnetic flux interlinking the RCW can be induced
in the magnetic tape by wrapping a magnetic tape around the
RCW, and the proximity effect can be suppressed.
Nonmagnetic insulators are effective in reducing the skin
effect. The magnetic flux generated when an ac passes through
the RCW flows in an elliptical shape and interlinks with the
corners of the RCW. Due to the interlinkage magnetic flux,
a spiral electric field is generated according to Ampere’s law,
and the current concentrates at the corners of the RCW. This
is the physical phenomenon of the skin effect. By loading a
magnetic tape and a nonmagnetic insulator, the magnetic flux
interlinking the corners of the RCW is guided by the magnetic
material and bypassed by the nonmagnetic insulator. Thus,
the current concentration at the conductor corners is relaxed,
and ac copper loss can be reduced. However, dimensions of
nonmagnetic insulators and the thickness of the magnetic tape
differ, depending on the operating conditions [25], [28], [29].
Therefore, in this article, the width and thickness of the
nonmagnetic insulator are 5.0 and 0.2 mm, respectively,
and the thickness of the magnetic tape is 0.3 mm. These
are the effective dimensions for reducing ac copper loss
under the operating conditions [29]. The primary and sec-
ondary sides are insulated by winding insulating paper several
times.
PC40 (TDK Corporation, Tokyo, Japan), which is Mn–Zn
ferrite, was used as the core. The iron loss of Mn–Zn ferrite
has negative temperature characteristics and takes a minimum
value at a specific temperature. However, after the iron loss
reaches the minimum value, temperature coefficient becomes
a positive value, and the iron loss increases monotonically as
the temperature increases. Therefore, Mn–Zn ferrite has a risk
of thermal runaway, which causes the temperature rise due to
heat generation by the core and winding losses [30], [31].
To prevent this thermal runaway, the temperature rise in
the winding should be as low as possible. PC40, which is
the core of this transformer, has a minimum iron loss at
363 K (90 ◦ C). Therefore, the operating temperature of this
transformer must be less than 363 K (90 ◦ C). The temperature
rise in the transformer core and windings must be less than
20 K when the temperature margin is 10 K because the
ambient temperature of the transformer changes from 248
(−25 ◦ C) to 333 K (60 ◦ C).
SHIMURA et al.: AC COPPER LOSS REDUCTION IN HIGH-FREQUENCY TRANSFORMER FOR RAILWAYS 8402207

Fig. 3. A–A sectional view of the high-frequency transformer for railways (unit: mm).

Fig. 4. Structures of the magnetic tape (unit: mm). (a) Appearance. (b) B–B
sectional view.

Fig. 6. Complex relative permeability–frequency characteristics of the

magnetic tape (Bm = 5 mT).

magnetometer (Riken Denshi Company Ltd., Tokyo, Japan,

Fig. 5. DC magnetic properties of the magnetic tape.
B. Magnetic Properties of Magnetic Tape
Fig. 4 shows the structures of the magnetic tape. Consid-
ering the wrapping around the conducting wire, the magnetic
tape has a width of 10 mm, a magnetic layer of 0.1 mm,
and an adhesive layer of 0.025 mm to prevent twisting and
cracking. The magnetic tape not allows the magnetic layer to
be easily loaded on the conductor and makes it easy to control
the thickness of the magnetic layer.
Fig. 5 shows the dc magnetization characteristics of the
magnetic tape. They were measured using a vibrating sample
BHV-55), and the saturation magnetization was 0.72 T.
Fig. 6 shows the complex relative permeability–frequency
characteristics of the magnetic tape. The complex relative
permeability was measured using a B–H analyzer (Iwatsu
Electric Company Ltd., Tokyo, Japan, SY-8218) at a magnetic
flux density Bm of 5 mT. The complex relative permeability
of the magnetic tape was almost constant, regardless of fre-
quency, and μ = 9.3 and μ = 0.026.
III. M AGNETIC F IELD A NALYSIS OF H IGH -F REQUENCY
T RANSFORMER FOR R AILWAYS
A. Analysis Conditions
The A–A sectional view of the high-frequency transformer
for railways (Fig. 3) was used as an analysis model, and RCW
and MRCW were applied to the windings.
Table II shows the analysis conditions. JSOL’s
JMAG-Designer ver. 18.2 was used for the analysis, and a

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8402207
TABLE II
A NALYSIS C ONDITIONS
Fig. 7. AC copper loss of the high-frequency transformers using RCW and
MRCW (I p = 31.6 A, f = 16 kHz, and depth: 100 mm).
2-D frequency-response magnetic-field analysis method was
employed. The plane coordinate model was used because a
2-D analysis model was employed in which the xy-coordinate
plane was extruded by 100 mm in the z-axis.
B–H analyzer was used to measure the complex perme-
ability of the core, PC40 (Iwatsu Electric Company Ltd.,
SY-8218).
The result complex relative permeability characteristics of
the magnetic tape are shown in Fig. 6.
Assuming the rated drive condition, the analysis was per-
formed with the primary side current I p = 31.6 A, frequency
f = 16 kHz, electric power Po = 15 kVA, and rated load
Ro = 28  connected to the secondary side.
B. Analysis Results
Fig. 7 shows the ac copper loss of the high-frequency
transformers using RCW and MRCW. The dc copper loss
was 5.21 W for both RCW and MRCW. The ac copper loss
in RCW and MRCW was 8.39 and 6.08 W, respectively.
Applying MRCW, a loss of 0.21 W was generated on the
magnetic tape, but the copper loss was reduced by 16.9%
compared to that of RCW. The 2-D planar coordinate model
used in the analysis is a part of the actual transformer shown
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IEEE TRANSACTIONS ON MAGNETICS, VOL. 57, NO. 11, NOVEMBER 2021
Fig. 8. Impedance characteristics of the high-frequency transformers for
railways. (a) Resistance R. (b) Inductance L p . (c) Inductance L sh .
in Fig. 4, and the winding section is considered only about
half of the actual length in the analysis. Therefore, the actual
loss can be predicted to be larger than the result in Fig. 7. The
magnetic tape used did not have a considerable impact on the
iron loss of the core, which was 37.7 W for both RCW and
MRCW.
IV. I MPEDANCE AND H EAT-G ENERATION
C HARACTERISTICS OF H IGH -F REQUENCY
T RANSFORMERS FOR R AILWAYS
A. Impedance Characteristics
We fabricated high-frequency transformers for railways
using RCW and MRCW, respectively, and evaluated their
impedance characteristics based on the analysis results.
An impedance analyzer (KEYSIGHT Technology, Tokyo,
Japan, E4990A) was used for measurement of the frequency
characteristics of the high-frequency transformers shown
in Fig. 8.
SHIMURA et al.: AC COPPER LOSS REDUCTION IN HIGH-FREQUENCY TRANSFORMER FOR RAILWAYS 8402207

Fig. 9. Heat-generation characteristics measurement circuit ( f = 16 kHz, I p = 31.6 A, and Is = 23.1 A).

Fig. 8(a) shows the resistance R measured from the primary

winding with the secondary shorted, which is close to that
during actual operations. The dc resistance was 12.1 m
for both RCW and MRCW. At the drive frequency f =
16 kHz, the resistance R of RCW and MRCW was 28.9 and
25.3 m, respectively, and a 12.5% reduction in resistance can
be attributed to the use of MRCW-based transformer. This is
because the ac resistance caused by the skin and proximity
effects was reduced by wrapping the nonmagnetic insulator
and magnetic tape.
Fig. 8(b) shows the inductance L p measured on the pri-
mary winding with the secondary opened. At the drive
frequency f = 16 kHz, L p of RCW and MRCW was
4.82 and 4.62 mH, respectively. Wrapping the magnetic Fig. 10. Heat-generation measurement points using a thermocouple.
tape, the mutual inductance between the primary windings (a) Winding. (b) Core.
decreased, thereby reducing L p .
Fig. 8(c) shows the inductance L sh measured on the primary
winding with the secondary shorted. At the drive frequency shown in Fig. 9 to confirm the role of magnetic tape in
f = 16 kHz, L sh of RCW and MRCW was 1.88 and 3.65 μH, reducing heat generated in the high-frequency transformer.
respectively. By wrapping the magnetic tape, the leakage flux The measurement was performed at a frequency f = 16 kHz,
increased, which significantly increased L sh . However, there a primary current I p = 31.6 A, and a secondary current Is =
was no problem in driving because L sh was sufficiently smaller 23.1 A, assuming a rated drive, and a K-type thermocouple
than L p . (MOTHERTOOL Company Ltd., Nagano, Japan, TPK-01)
Additionally, the self-resonance frequencies of RCW and was connected to the winding and core.
MRCW were 158 and 150 kHz, respectively, which are Fig. 10 shows the heat-generation measurement points using
sufficiently large for drive frequency. a thermocouple. It is preferable to measure the heat generation
of the innermost winding and inner core, which generate a
large amount of heat. However, due to structural restrictions,
B. Heat Generation Characteristics the heat generation of the secondary winding wound on the
The heat-generation characteristics of the transformer wind- outermost circumference and that of the uppermost core were
ing and core were measured using the measurement circuit measured. Considering the effect of room temperature on

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8402207
Fig. 11. Temperature rise versus time characteristics of the high-frequency
transformers using RCW and MRCW (I p = 31.6 A and Is = 23.1 A).
(a) Winding. (b) Core.
the temperature rise, the heat-generation characteristics were
evaluated using the temperature rise obtained by subtracting
the room temperature from the temperature measured by the
thermocouple.
Fig. 11 shows the heat-generation characteristics of the
high-frequency transformers. Both RCW- and MRCW-based
transformers were thermally saturated at 420 min. The satura-
tion temperature rise in the winding of the RCW- and MRCW-
based transformers were 22.9 and 18.0 K, respectively, and
the temperature rise was reduced by 21.4% [Fig. 11(a)].
Further, the saturation temperature rise in the core of the
RCW- and MRCW-based transformers were 17.3 and 13.3 K,
respectively, and the temperature rise was reduced by 23.1%
[Fig. 11(b)].
By wrapping the magnetic tape, the ac resistance
induced by the skin and proximity effects was reduced,
and the heat generation of the winding was suppressed.
Thereby, the temperature rise of the core was sup-
pressed, and the risk of thermal runaway of the core was
reduced.
V. C ONCLUSION
In this article, we designed and fabricated high-frequency
transformers for railways with reduced skin and proximity
effects. This study is summarized as follows.
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IEEE TRANSACTIONS ON MAGNETICS, VOL. 57, NO. 11, NOVEMBER 2021
To confirm the reduction of ac copper loss in the high-
frequency transformer for railways using magnetic tape,
magnetic field analysis and loss comparison of the RCW-
and MRCW-based transformer were performed. AC cop-
per loss due to the skin and proximity effects in MRCW
was 16.9% lesser than that of RCW. The analysis of the
impedance characteristics of the transformers showed that the
primary resistance with secondary shorted was close to that
in the actual operations. It was reduced by 12.5% (from
28.9 to 25.3 m).
Based on these results, ac copper loss in electrical equip-
ment due to the skin and proximity effects can be reduced by
wrapping a magnetic tape around a coil. Thereby, reducing
heat generation of electrical equipment.
The proposed technique is not limited to high-frequency
transformer for railways, but can reduce ac copper loss in
rectangular wires used in electrical equipment such as motors,
inductors, and transformers, thereby suppressing heat genera-
tion in electrical equipment.
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