TRANSFORMER DESIGN TECHNOLOGY

The design sheet in Excel format contains the complete technology of

Transformer design.

Any one can design Transformers using the above Design Sheet.
The major parameter of the transformer design is the Core Circle and
the Coil Stack Height. Everything else automatically follows. We have
no control over them. In case the resulted transformer is not
satisfactory we have to change either the core circle, or the stack
height or both of them.

The first step in the design is to find out the No. of phases, voltage and
rating of the transformer and the Vector group from the customer
spec.

Depending on the type of connection (Star or Delta) winding voltage is

to be calculated.
In case the connection is STAR, then the winding voltage is
Transformer Voltage divided by 1.732. In case of Delta Connection it is
the same as Transformer voltage.

Depending on the Voltage and the tapings the voltages on the various
windings are to be decided. In case the range of the tapings are more
separate tap windings may be required.

Also depending on the voltage some times high voltage terminal may
be required at the middle of the winding height. Two or more (always
even Nos.) conductors in parallel half wound in upward direction and
half in down ward direction from the middle may be required.

Also tapings to be provided in the middle of the winding or at the end

is to be decided.

Once this decision is made then assume a core circle. For preliminary
design 93% of the circle diameter can be assumed as the core area.
Also a factor 0.965 is to be added to take into account the insulation
coating of the CRGO. (In the final design thearea is to be calculated
from the optimum stacking of the core sheets)

From the core area and a flux density of 1.65 Tesla the volt per turn is
calculated.
(In Excel sheet the LV No.\of turns is selected which automatically
calculates the Flux density. The No of turns is adjusted in such a way
that the flux density is in between 1.55 and 1.7

The stack height is also assumed and the type of winding ( Layer,
Helical or DISC is decided depending on the No of Turns. The average
radial spacer thickness is adjusted to be beteen 3.,2 and 4.8.

The conductor size is decided to limit the current density between 3

and 4. ( This is later finalized after checking HOOP Stress and Axial
Compressive Force.

The area of the conductor is calculated by the Excel sheet after taking
into account the loss due to rounding off of the conductor corners.

Depending on the I^2R Loss it is decided whether a vertical duct is required or not. Thus
the width of the windings are finalized which allows us to calculate the leakage
impedance of the transformer. If the impedance value is same as what we need then the
design is complete. If the value of impedance is less than what we need then turns are
increased or stack height is reduced if possible and the whole exercise is repeated until
we get the correct impedance value.

The formula for calculation of impedance is available in the Excel sheet. Please note that
the impedance is directly proportional to the square of the No. of turns and inversely
proportional to the coil stack height. It also varies with the width and average diameter of
the windings and the gap between the windings. (The gap between the winding has 3
times the influence on the impedance than the width of the windings.)

The gap between the windings and the losses in the Tank are a matter of experience from
the designs already executed.