DESIGN

>> DESIGN OF SINGLE PHASE 1KVA, 50HZ, 230/110V TRANSFORMER:

I) CORE SECTION:

Volt ampere rating of Transformer = 1000 VA Turns per volt, Te = 1.6 Flux, m = 1/(4.44*f* Te) = 1/(4.44*50*1.6) m = 2.81*103 Wb Taking Flux density as 1.3 Wb/m2 So, Net iron area of core, Ai = m/Bm = 2.81*103/1.3 Ai = 2.16*103 mm2 Gross core area, Agi = 2.16*103/0.9 Agi = 2.406*103 mm2 Taking a Square section for central limb. Width of central limb, A = Sq. rt. (Agi) = Sq. rt. (2.406*103) A = 49.05 mm

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II) PRIMARY WINDING:

Taking efficiency of transformer, = 85% So, Primary winding current, Ip = VA/(*Vp) = 1000/(0.85*230) Ip =5.11 A Taking current density as p = 2.5 A/mm2 Area of primary winding conductor, ap = Ip/p = 5.11/2.5 ap = 2.046 mm2 Diameter of bare conductor = Sq. rt. (4*ap/) = Sq. rt. (4*2.046/3.14) = 1.614 mm Using enamelled conductors. The nearest standard conductor has bare diameter, d = 1.7 mm. The diameter of insulated conductor, d 1= 1.81 mm with medium covering of insulation. Space factor for primary winding, Sf = 0.8*(d/d1) 2 = 0.8*(1.7/1.81) 2 = 0.703 Area of primary conductor used, ap = /4*(d) 2 = /4*(1.7) 2 ap = 2.269 mm2 Number of primary winding turns, Tp =Vp*Te = 230*1.6 Tp = 368 turns PAGE: 2

Window space required by primary winding, Wp = Tp*ap/Sf = 368*2.269/0.703 Wp = 1184.38 mm2

III) SECONDARY WINDING:

Secondary winding current, Is = VA/Vs = 1000/110 = 9.09 A Area of secondary winding conductor, as = Is/s = 9.09/2.5 as = 3.639 mm2 Diameter of bare conductor = Sq. rt. (4*as/) = Sq. rt. (4*3.639/3.14) = 2.151 mm Using enamelled conductor for secondary winding. The nearest standard conductor has bare diameter, d = 2.240 mm The diameter of insulated conductor, d1 = 2.365 mm Space factor for secondary winding, Sf = 0.8*(d/d1) 2 = 0.8*(2.240/2.365) 2 Sf = 0.717 Area of secondary conductor used, as = /4*(d) 2 = /4*(2.240) 2 as = 3.940 mm2

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 When calculating the number of secondary winding turns an allowance of 5 percent extra turns are made to compensate for the voltage drop in the winding. Number of secondary winding turns, Ts = 1.05*Vs*Te = 1.05*110*1.6 Ts = 185 turns Window space required by secondary winding, Ws = Ts*as/Sf = 185*3.940/0.717 Ws = 1015.5 mm2

IV) STAMPING SIZE:

Total window space required, Aw = 1.2*(space required for primary and secondary winding) = 1.2*(Wp+Ws) = 1.2*(1184.38+1015.5) = 2639.83 mm2 Aw = 10.39 Sq. inch Now, we have to select a stamping which gives: a) Width of central limb, A = 49.05 mm A = 1.93 b) Area of window, Aw = 2639.83 mm2 Aw = 10.39 Sq. inch Using a combination of E and I stampings.

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 From figure:

Diagram of lamination for small transformers (E-I type):

i)
ii) iii) iv) v) Now,

A = 2 B = 7.25 C = 6.75 D = 1 E = 1 Width of window, Ww = (B-A-2*D)/2 = (7.25-2-(2*1))/2 Ww = 1.625 inch Height of window, Hw = C-2*E = 6.75-(2*1) Hw = 4.75 inch

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 Area of window provided, Aw = Ww*Hw = 1.625*4.75 Aw = 7.718 Sq. inch Width of central limb, A = 2 = 50.08 mm >> Thus, it satisfies the above conditions, which are required.

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SIGN:

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