1.

Introduction
1.1 1.2 1.3 1.4 1.5 1.6 General 1 Literature survey Research objective Solution proposed Scheme 3 Expected results 3

Contents 1

2 2 2

2. Basic Theory of Transformer

2.1 What is Transformer
2.1.1 2.1.2 2.1.3

4
4

Explanation Step up/Unit transformers Step down/Substation transformers

2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11

History of Transformer 5 Basic Principles 6

2.3.1 2.4.1 2.5.1 Induction Law

Ideal Transformer
Practical Transformer

7 9

Leakage Flux

Effect of Frequency

Dot Convention 10 Energy Losses 10 EMF Equation of Transformer Equivalent Circuit 12 Classification 13 Types of Transformers 14
2.11.1 2.11.2 2.11.3 2.11.4 2.11.5 2.11.6 2.11.7 2.11.8 2.11.9 Auto Transformer Polyphase transformers Generator transformers Unit auxiliary transformers Station transformers Receiving station transformers Distribution transformers Instrument Transformers Testing Transformers

12

2.12 Construction

17

2.12.1 Laminated cores

2.12.2 2.12.3 2.12.4 2.12.5

Laminated steel cores Solid cores Toroidal cores Windings

2.13 Parallel Operation of Transformers 2.14 Applications of Transformers 20

19

3. Transformer Design Theory

21

3.1

Core Design
3.1.1 3.1.2 3.1.3 3.1.4 3.1.5 3.1.7 3.1.8 3.1.9 3.1.10

21

Core Characteristics Output equation -emf per turn of winding (Et ) Selection of core stacks (K) Calculation of primary turns Selection of flux density (Bm) Calculation of gross area of iron core (Ag) Staking factor Calculation of core diameter Calculation of steps

3.2

Design of LT winding
3.2.1 3.2.2 3.2.3 3.2.3 3.2.4 3.2.4 3.2.5 3.2.6 3.2.7

25

Calculation of LT current Choice of current density Area of LT winding Rectangular strips of low voltage conductor Calculation of actual area of rectangular conductor Number of layers for LT winding Insulation of LT winding Calculation of axial length of LT winding (Lc2) Calculation of radial width (b2)

3.3

Design of HT winding
3.3.1 3.3.2 3.3.3 3.3.4 3.3.5 3.3.6 3.3.7

29

Calculation of HT turns Calculations of HT area and diameter HT winding in the form of packets Number of layers for HT winding Calculation of axial length of HT winding Calculation of radial width of HT winding Radial calculations

3.4

Losses and impedance calculation

3.4.1 3.4.2 3.4. 3.4.5 3.4.6

32

Calculation of LT Cu losses Calculation of HT Cu losses Stray losses Calculation of total core losses Calculation of percentage reactance, resistance, impedance

3.5

Performance parameters
3.5.1 3.5.2 3.5.3 3.5.4

34

No load losses No load current at rated and 112.5% voltage Calculation of efficiency Calculation of voltage regulation

3.6 3.7 3.8 3.9

The design of tank

3.6.1 3.6.2 3.7.1 3.8.1

36 38 39 41

Three modes of heat transfer Calculation of temperature rise () Calculation of number of tubes required Use of SMPS technology for obtaining high frequency

Design of cooling system Method of increasing frequency

Benefits of using SMPS technology

4. Design of 10KVA Transformer

4.0 4.1 4.2 4.3 Design of transformer Core design 44
4.1.1 4.1.2 4.2.1 4.2.3 4.3.1 4.3.2 4.3.3 Step Calculations Results

43
43

Design of LT winding
Radial calculations Results

51 53

Design of HT winding
Tapping calculations Radial calculations Results

4.4

Losses and impedance calculations

4.4.1 4.4.2 4.4.3 4.4.4 4.4.5 4.4.6 LT Cu losses HT Cu losses Total Cu losses Core losses Results No-Load losses

58

4.5

Performance parameters
4.5.1 4.5.2 4.5.3 4.5.4 4.5.5

64

No load current at rated voltage No load current at 112.5% voltage Voltage regulation Efficiency Performance Figures

4.6

Design of cooling system

70

5. Design of 10KVA Transformer(High Frequency)

72

5.0 5.1 5.2 5.3 5.4

Design of transformer at high frequency Design of transformer 73 Core design 74

5.2.1 5.2.2 5.3.1 5.3.2 5.4.1 5.4.2 5.4.3 Step Calculations Results

72

Design of LT winding
Radial calculations Results

79 82

Design of HT winding
Tapping calculations Radial calculations Results

5.5

Losses and impedance calculations

5.5.1 5.5.2 5.5.3 5.5.4 5.5.5 5.5.6 LT cu losses HT cu losses Total cu losses Core losses Results No-load loss summery

85

5.6

Performance parameters
5.6.1 5.6.2 5.6.3 5.6.4 5.6.5

90

No load current at rated voltage No load current at 112.5% voltage Voltage regulation Efficiency Performance figures

5.7

Design of cooling system

94

6. Comparison Between High Frequency and Normal Design

6.1 6.2 General 96 Transformer design
6.2.1 6.2.2 6.2.3 6.2.4 6.2.5 6.2.6 6.2.8 6.2.9 6.2.10 6.2.10 6.2.11

96

97

Technical efficiency Economic efficiency Cost Capital cost Running cost Depreciation in capital cost Core of transformer LT design HT design Cost of electronic circuit Total cost reduction

6.3 6.4

Technological comparison
6.4.1 6.4.2 6.4.3 6.4.4 6.4.5 6.4.6 6.4.7 6.4.8

102 108

6.3.1 SMPS and linear power supply comparison

Some Important parameters associated with the design

Restrictions on number of turns Temperature rise limit Losses Thermal resistance Balancing core and winding losses Frequency Core Selection: Material Core Selection: Shape