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Inductors are cornerstone components in power electronics converters. Since winding loss is the dominant loss mechanism in these components, its accurate measurement is fundamental for the validation of the inductor&#x2019;s operation and design. The techniques for the winding resistance <inline-formula> <tex-math notation="LaTeX">$R_{w}$ </tex-math></inline-formula> measurement in power inductors can be classified into two groups, indirect and direct. Both techniques use coupled inductors to separate winding and core power losses. If coupled inductors with non-zero winding mutual resistances <inline-formula> <tex-math notation="LaTeX">$R_{w,m}$ </tex-math></inline-formula> are used, invalid results are obtained with these techniques. Understanding the meaning of <inline-formula> <tex-math notation="LaTeX">$R_{w,m}$ </tex-math></inline-formula> in coupled inductors is complex. In this paper, the impact of <inline-formula> <tex-math notation="LaTeX">$R_{w,m}$ </tex-math></inline-formula> on the inductor <inline-formula> <tex-math notation="LaTeX">$R_{w}$ </tex-math></inline-formula> measurement techniques is demonstrated and practical guidelines for the design of the zero <inline-formula> <tex-math notation="LaTeX">$R_{w,m}$ </tex-math></inline-formula> coupled inductors are given. Particularly, the location of the auxiliary winding for the direct technique is investigated. In order to compare the <inline-formula> <tex-math notation="LaTeX">$R_{w}$ </tex-math></inline-formula> measurement techniques and to validate the coupled inductor&#x2019;s <inline-formula> <tex-math notation="LaTeX">$R_{w,m}$ </tex-math></inline-formula> impact, two different inductors are built and tested. The results are compared with the values for <inline-formula> <tex-math notation="LaTeX">$R_{w}$ </tex-math></inline-formula> calculated by FEA simulation. It is found that only the direct technique with an auxiliary winding carefully designed and located following the guidelines given in this paper makes the accurate measurement of <inline-formula> <tex-math notation="LaTeX">$R_{w}$ </tex-math></inline-formula> in power inductors possible.

Winding Resistance Measurement in Power Inductors - Understanding the Impact of the Winding Mutual Resistance