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Report Transformer Design 4Final touch

Machine Design (Khulna University of Engineering and Technology)

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KHULNA UNIVERSITY OF ENGINEERING

& TECHNOLOGY

Report on transformer design

SUBMITTED TO:

Dr. Md. Habibullah

Professor
Dept. of EEE, KUET.

Abu Syed Md. Jannatul Islam

Assistant Professor
Dept. of EEE, KUET.

SUBMITTED BY:

1. Thasin Mohammad Zaman (1903069)

2. Mridul Mondol (1903070)
3. Syed Mashrur Rubaiyat (1903071)
4. Nuzmus Sakib (1903072)
5. Shihabul Ehsan (1903073)
6. Partha Jyoti Roy (1903074)
7. Khan Mahmud (1903084)

Date of Submission:

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Objectives:
After this design is complete, we will be able to:
1. Learn the fundamentals of transformers.
2. Learn about the process involved in developing a transformer.
3. Learn about the fundamental specifications needed to create a transformer.
4. Be proficient in optimal design.

Introduction:
A transformer is a passive component that transfers electrical energy from one electrical
circuit to another circuit, or multiple circuits, without changing the frequency. Transformer
can increase or decrease the voltage with corresponding decrease or increase in current.
Transformer works on Faraday's law of mutual induction. Faraday’s law of electromagnetic
induction states that, when a change takes place in the magnetic flux which is linked with a
circuit, an electromotive force current will induce in the circuit. Only alternating current
(AC), or oscillating electrical flow, is compatible with transformers. The magnetic field in the
core changes when alternating current passes through the primary coil. The secondary coil is
connected to the shifting field, which causes an electric current to flow there as well. The
voltage of the secondary coil varies based on the number of turns in each coil, but it is
essentially an exact replica of the current in the primary coil in the case of shape.
In other words, a transformer uses the magic of magnets and coils to transfer electrical power
from one circuit to another without altering the frequency.

Construction of Transformer:
Basically, a transformer consists of two inductive windings and a laminated steel core. The
coils are insulated from each other as well as from the steel core. A transformer may also
consist of a container for winding and core assembly (called as tank), suitable bushings to
take out the terminals, oil conservator to provide oil in the transformer tank for cooling
purposes etc. The figure at left illustrates the basic construction of a transformer. In all
types of transformers, core is constructed by assembling (stacking) laminated sheets of
steel, with minimum air-gap between them (to achieve continuous magnetic path). The steel
used is having high silicon content and sometimes heat treated, to provide high permeability
and low hysteresis loss. Laminated sheets of steel are used to reduce eddy current loss. The
sheets are cut in the shape as E, I and L. To avoid high reluctance at joints, laminations are
stacked by alternating the sides of joint. The construction of transformer parts is as follows:
A. Magnetic circuit
B. Electric circuit
C. Core construction
D. Dielectric Circuit
E. Conservator
F. Breather
G. Explosion Vent
H. Radiator
I. Bushing

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J. Windings
K. Conservatory Tank

Fig 1.1: Basic structure of a transformer

Types of Transformers:
Transformers can be classified into different categories depending upon their end- use,
construction, supply, and purpose.
On the Basis of Design:
Core Type Transformer: A core-type transformer is a type of transformer where two coils
of wire (windings) are wound around a laminated silicon steel core. One winding is
connected to the power source (primary winding), and the other to the load (secondary
winding). This design enhances the magnetic coupling between the windings, making it more
efficient in transferring electrical energy between circuits.
Shell Type Transformer:
A shell-type transformer is a type of transformer configuration where the primary and
secondary windings are wound around a central core, with one winding surrounding the
other. The core is typically made of laminated sheets. This design offers certain
advantages in terms of mechanical stability and ease of cooling, making it suitable for
specific applications in electrical power systems.

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Fig 1.2: Basic structure of core type and shell type transformer

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On the Basis of Supply:

Single Phase Transformer: A single-phase transformer is a type of transformer that
operates with a single alternating current (AC) input and output. It has two coils, a primary
winding connected to the power source, and a secondary winding delivering power to the
load.
Three Phase Transformer: A three-phase transformer consists of six windings, three for the
primary and three for the secondary. The windings on each side (primary and secondary side)
can be connected in either delta or star configurations. These windings can be viewed as
separate single-phase windings. In theory, three single-phase transformers can be connected,
creating a three-phase transformer.

On the Basis of Purpose:

Step Up Transformer:
A step-up transformer elevates voltage and lowers current, accomplished by having more
turns in the secondary winding than in the primary winding. This type of transformer is
commonly used to increase voltage for long-distance power transmission.
Step Down Transformer:
A step-down transformer reduces voltage while increasing current, achieved by having fewer
turns in the secondary winding than in the primary winding. This type of transformer is
commonly used to decrease voltage for safer use in households and businesses.

Different types of Winding that are used in transformer design:

a. Cylindrical
b. Helical
c. Double helical
d. Multi-layer helical
e. Cross-over
f. Disc and continuous dis

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Core Design
Specifications:
Apparent Power, VA = 200 VA
Primary Voltage = 220 V
Secondary Voltage = 100 V
Frequency, f = 50 Hz
Type: single phase, shell type

Calculation:
As it is a single phase, shell type transformer,
Let, Utilization factor, Ku = 2.55 ×10−2
Maximum flux per columb, ϕ =ku
√ KVA
f
Let the operation is intermittent operation.
−3
=1.61× 10 Wb

So, Let, B = 1.1 Wb /m2

ϕ 2
The area of net iron section, Airon = =1460 m m
B
The column width is, C = √4 VA=3.76 cm
Therefore, a commertial lamination is selected with
external size 100x120
column size 40x60
window size 20x60
having .5mm thickness including the paint insulation.

LABTEST DATA:

I = 0.127A
O.C Test
*Core Loss is negligible
Vs = 17 V
IP = 0.9 (Rated Current)
S.C Test
p.f = 0.99
Copper Loss = 14 W

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The net thickness of iron package is:

Air
Lp = = 36.5mm
C
Assuming packing coefficient , Ks = 0.9
Let paint insulation of thickness = 0.5 mm
Lp
The gross thickness = =40.5 mm
Ks
Lpo
Corresponding to =81 ( laminations )
thickness
To mount the core the laminations are inserted into a 40x40 nylon reel; the laminations are
alternately inserted so that the joints are staggered.

Calculation of Windings:
The voltage per turn, e = 4.44 fϕ=0.357 V
V1
The number of primary turns , N 1= =616 turns
e
Voltage drop at secondary side is not more than 5%
Δ V =V 2× 5 %=5V
V 2+ Δ V
So, Secondary turns, N2 = =295
e
Efficiency = 95%

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A
The primary current, I1 = =0.96 A //Let, TRM, A = 200
V 1. η
A
Let the operation is intermittent operation so let current density σ =3.5 2
mm
I1 2
Corresponds to a copper section of Acu1 = =0.275 mm
σ
Commercial diameter, ϕ 1=0.59 mm
A
The secondary current, I 2= =2 A
v
I2 2
This corresponds to a copper area of , Acu2 = =0.57 m m
σ
Commercial diameter, ϕ 2=0.852 mm

Practical calculation:
We are using E,I type core. After measuring the dimensions, we get the followings:
Unowned Column Height = 87.5mm
Unowned column width = 22.5mm
Owned Column Height = 87.5mm
Owned Column width = 45mm
So, Core Size = 135 * 132.5
Reel Dimension = 1.8*1.75 square inch
Lamination needed=86
Primary turns=616 , Wire Gauge=23(0.610mm)
Secondary turns=295, Wire Gauge=21(0.813mm)
Useful height of the reel,h=66mm
(n1=66/(1.05*0.610)=38,n2=66/(1.05*0.813)=77)
The number of layer is,
Sp=616/38=17
Ss=295/77=5

Discussion and conclusion:

In this project, we have designed a single-phase shell type transformer of 200 VA. For
designing the core, we used E & I type laminations, which were closely packed. As a
result, the output voltage for input voltage of 220 volt was nearly 100 volts as rated.
The insulation used for the designing purpose was masking tape and Leatheroid paper. In
primary winding design, two winding were used & in secondary one insulation paper
used. Insulation also used to prevent any contact between core and winding.
Turns ratio of our designed transformer was nearly 2.09. But the turns ratio was slightly
higher for lower primary voltage (like 15, 20 Volt). But the turns ratio was nearly perfect
for higher voltages.

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As the core was tightly packed, there is no air gap. As the result, there was nearly no
noise when the transformer was tested.
This design of transformer successfully meets the specified efficiency of 95% and
ensures a voltage drop on the secondary side not exceeding 5%. The careful selection of
materials, winding techniques, and insulation contributed to the optimized transformer
performance.
After the design, we measured 227 volts and 104 volts for primary and secondary
voltages respectively. This small inconsistencies between calculated and actual values
may arise due to practical limitations in manufacturing and the inherent complexities of
the real-world applications. Factors such as material variations, manufacturing tolerances,
and environmental conditions can impact the final transformer performance. Despite
great care being taken to calculate and apply the design parameters exactly, these
fundamental uncertainties emphasize the value of practical considerations in transformer
design and the necessity of thorough testing and validation procedures to guarantee the
transformer's performance meets the intended specifications.
The necessity of careful design considerations in obtaining desired transformer
performance characteristics is demonstrated by this project. The information gathered
from this experiment can be used to improve power distribution and energy efficiency in
transformer designs in the future.

A Nonconforming Phenomena:
Theoretically, the H.V side of the winding should be outside and the L.V side should be
inside. But, we have done the converse. The reason behind it is that the SWG of the H.V
is 23 and L.V is 21. It means the wires of H.V side is thinner than the L.V side. We know
that the resistance of thin wire is large. If we put the L.V side inside and the H.V side
outside then the diameter of the axis on which H.V side winding will be done will
increase as a result we need much wire of 23 gauge and as its resistance is higher than
that of 21 gauge the resistance will be large which will cause much loss in our
transformer. Therefore to reduce the loss, the H.V side winding is putted inside and the
L.V side winding is putted outside.
N.B: This idea is enough good for low value transformers like ours. But for high value
transformer the conventional theory is abided by.

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