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A transformer is a device with two or more stationary electrical ckt that are conductively disjointed but magnetically coupled by a common timevarying magnetic Field. Transformer are basically passive device for transforming voltage and current one of the windings, generally termed as secondary winding, transformer energy through the principal of mutual induction and drivers power to the wad. The voltage level at primary and secondary windings are usually different and any increase or decrease of the secondary winding voltage is accompanied by corresponding decrease or increase in current. Transformer are among the most efficient machines 951. efficiency being common in lower capacity ranges. While efficiency of the ordered of 99 % is achievable in high capacity range. Theoretically there is no upper limit to the
power handing capacity, transports constraints, handling facilities etc. Being the limiting factors, the lower limit is governed by the allowable no-load loss. The physical basis of transformer is mutual induction between two ckt. Linked by a common magnetic field. The primary ckt carrying a current has associated with it as a manifestation of the electrical phenomenon, of current flow, a magnetic field at any pt in the surrounding medium will vary in Both magnitude and direction in accordance with change of current with time. The secondary ckt being in the vicinity of primary ckt will link some of the magnetic flux produced by primary. With an alternating primary current and therefore flux, the changing linkages will produced in the secondary winding an e.m.f.
Due to sinusoidal current flowing through in a primary winding a flux almost sinusoidal is produced in the iron whole of waveform as shown above. If supply frequency is F then the frequency of supply will also F since time to complete F cycle = 1 sec. So time to complete 1 cycle = 1/F sec.
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time interval for change in Flux = m0 = 1/4F -0 We know that, Form factor = R.M.S. = 1.11 for W Av.
Average value So R.M.S. value of voltage induced in each turn coil = 1.11 x 4 x F x m If primary turns = N 1 R.M.S. voltage induced in primary i.e. 1 = 1.11 x 4 x F x M x N1 1 = 4.44 x F x M . N 1 If secondary turns = N2 R.M.S. voltage induced in secondary i.e. 2 = 1.11 x 4 x F x M x N1 2 = 4.44.F. M . N2
Also For Xmer Primary volt. amp = Sec. Volt. amp. E1 . I1 From equation (1) and (2) Ep Es Also for Xmer Primary Flux Linkage = Secondary Flux Linkage. Np Ip = Ns .Is K is known as constant voltage transformation ratio. = Np Ns = Is Ip = E2 . I2 (2)
Vp
Eb
Magnetizing components (Im OR I ) Core use components (Ic) And no load primary current (Io) is phasor sum of I and Ic OR Io = I + Ic
ii)
(1) Magnetizing component :I is responsible for production of working flux in Xmer core. This current has behind the applied voltage by 900. (II) Core loss componets is presents (1) Hysterisis loss (Ph) (2) Gady current loss (Pe) in the core. This current is resistive in nature so, It is in phase. With applied voltage Vp Ic m Io Io = I + Ic
ON LOAD POWER FACTOR OF XMER :(1) LAGGING LOAD :- (INDUCTIVE LOAD). Vp=Ep Ip I1 Ic Io Im I2 I2 R e2 I2 x e2 V2 E 2 = G1
Vp = Primary applied volt E 1 = primary induced volt Ip = total primary current Io No load current I = mag. Comp. of current Ve2 Xe2
VpE1
E2
V2
RL + j x L
E1
I1X2
1
I1 Io
I2 I2 r1 V2 I 2R 2 E2 = E1 I2 X2
(1) Hysterisis Loss :- When alternating current flows through, primary winding, cyclic magnetization and demagntisation of X mer Core take place. So Heat is
To minimize hysterisis was CRCTO cold Rolled grain oriented steel or silicon steel is used. The permability of (RGO is very high more than 10.000.
II) EDDY CURRENT LOSSES :In X mer primary and secondary windings alternating current Flows as per Faradays Law of electromagnetic induction and lene`s law opposite current are set-up in the Iron core due to which I 2R losses takes place in the Iron core. Since this loss is due to Eddy current. It is called as Eddy current loss.
It is clear that to Reduce eddy current loss. Eddy current should be loss. So electrical resistance of iron core in the path of eddy current should be more. To increase the electrical resistance of iron core the core is made-up of, thin laminated strips insulated to each other and assembled by nut-bolts. The thickness of laminated is around 0.3 mm (1/3), also silicon increases the electrical resistance of X mer core so silicon steel is used. But more is the silicon steel becomes brittle so silicon up to 4 % is added. Eddy current loss is also dependant upon. (III) VARIABLE LOSSES :This losses depends upon primary and secondary winding resistance and currents flowing through them. RF primary currents Ip, primary Resistance R 1 and secondary current R 2 and secondary winding Resistance R2. Then total variable loss = Ip2R1 + Ib2R2 This is called variable loss because it is dependant upon load current. Pe F2. Bm2
REGULATION
When Xmer is loaded with a constant primary voltage, then the secondary terminal voltage drops (assuming lagging power factor ); It will increase if power factor is leading because of its internal resistance and leakage reactance. Let, V 2 = Secondary terminal voltage at no-load V 2! = Secondary terminal voltage at load %R = V2 - V2! x 100 V2 Then % Regulation of a loaded Xmer at any power factor is given as = ( R Cos + X sin ) + ( XCos - R sin ) 200 Where R = % of Resistive drop X = % of reactive drop COS = Lagging or leading P.F.
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EFFICIENCY
Efficiency of Xmer are (I) = = = O/P I/P out put out put + losses O/P O/P + const.loss(Pc) + variable loss (Pcu) II) % = I/P losses R 1p = Input Input % = 1 _ Losses Input losses Input
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Refer to Secondary
Rc
re2 = r2 + r1 ( N2 )2 N1 xe2 = x2 + x1 ( N2 )2 N1 Where, r1 = Primary winding resistance. r2 = Secondary winding Resistance. x1 = Primary winding Reactance. x2 = Secondary winding Reactance. RC = Resistance Representing core loss. X = Mag Reactance. N1 and N 2 = No of turns primary and secondary windings.
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(V2 .I2 cos 2 + Pi + I22 re2 )V 2cos 2 - V 2cos 2 (V2 . cos 2 + 0 + 2I2. re2) (V2 I2 . cos 2 + 0 + 2 I2. re2 )
(V2 .I2 cos 2 + Pi + I22 re2 )V 2cos 2 - V2 I2cos 2 (V2 . cos 2 + 2I2. re2) = 0 (V2 .I2 cos 2 + Pi + I22 re2 ) V 2cos 2 = V2 I2 cos 2 (V2 . cos 2 + 2I2. re2) V2 .I2 cos 2 + Pi + I22 re2 = V 2 I2 cos 2 + 2I22. re2 Pi + I22 re2 = 2I22. re2 Pi = I22. re2
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TYPES OF XMER
There are mainly two type X Mer are used. (1) (2) CORE TYPE SHELL TYPE The difference between these two X Mer are as CORE TYPE SHELL TYPE
(1) Winding surrounds the core (2) Winding have poor mechanical strength (3) More leakage reactance (4) Repairs easy (5) Better cooling of winding
(3) Less leakage reactance (4) Repair difficult (5) Better cooling of core.
Due to easy repairs and better cooling core X Mer are mostery more used than shell type XMer. Kinds of transformations Voltage transformations
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I2 I1
= =
N1 N2
= =
N1 N2 N1 N2
2
N1
V1
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Here V2 V1 V2 Volt ampear :As in any transformer the sec volt ampear or VA must equal the V.A. (J/P) as stated V1 V2 = I2 I1 N2 = N2 N1 = N2 V 1
TWO BASIC DESIGN EQUATION First is voltage equation & second is power capability equation. P = 0.707 J f WaB x 10-8 V = F = f = a = N = Applied Voltage form factor frequency Core crass sectional area No of turn on considered wndg
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Some time T is made to represent N/V T = 108 4FfaB It is assumed that Equation will be used with. Sinusoidal 9/P & So F is
immediately assigned the value of 1.11 this value. Combine with 4 gives 4.44. In place of 4 F N V = 108 4 .44 fa B
This Equation usually move practical for design purpose however to add conservation to them that enable a expressed in inches. & B in gauss. This conservation is accomplished by including the factor 6.45 in bottom line. (There are 6.45 Sq Cm to Square inch ) N V Or dividing N V = = 108 4 .44 x 6.45 fa B 3.49 x 106 faB = 108 28.64 fa B
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It this is compared to basic Equation. is now being used to replace a x B B = a B = flux density = total flux a = cross sectional area of core = V x 108 4FfN Which express total flux in core. Autotransformer losses and ratios R2 Vd2 N 1 V1 Vo Vin Vd1 R1
for this case the turn voltage ratio equation is N1 N2 = Vin - Vd1 Vo + Vd1 - Vd2
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Core Selection :All this discussion about alloy, lamination, toroids, cut cores, metal powder, ceramic & many chart is fine, interesting even later the moment of trust must arrive a choice must be made from wetter of possibilities. It you want to design power XMer . This statement immediately narrow the search because power XMer is a high flux application that is generally accepted that the core material for power X Mer should be run at high flux density at possible in order to keep XMer small & less costly. Volt ampear ratings :It the load is resistive in nature then they have power factor 1.0. It P.F. less than 1.0 then such load require X Mer of larger volt. Ampear capacity than that indicated by load expressed in watt motors for example have power factor less than 1.0.
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DESIGN
Output of Transformer :Let. m Ai Ac Aw D d kw Ei = = = = = = = = = main flux ; Bm = max. flux density wb/m 2 current density A/ m2 ; Agi = gross core area m 2 net core Area = Stacking factor x gross core area m 2 Area of copper in the window m2 Window Area m2 Distance between core centeres in Diameter of circumscribing circle m Window space factor f = frequency Hz Emf per turn Volt. No. of turn in primary and secondary of Win Curen in primary and Secondary or withal terminal voltage of primary & secondary of winding Area of conductors of primary & sec. Win m2 mean length of flux path in iron m length of mean turn of XMer Wind (M) Wt of active iron Kg. Gl = wt of cuppe kg.
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As Tp.Ip = Ts.Is = At if we neglect magnetizing emf. i) Single Phase Transformer The voltage induced in a transformer winding with T turns and excited by a source having a frequency f Hz Voltage per turn given by
Et = E = 4.44 f m (i)
The window in a single phase transformer contains one primary and one secondary windings. Total Cu area in window Ac = Cu area of primary winding + Cu are of secondary winding = pri. turns x area of pri. conductor + sec. turn x area of sec. turn = Tp . a p + Ts .as taking the current density to be the same in both primary and secondary winding a p = Ip / and as = Is /
Total conductor area in window Ac = Tp.Ip/ + B.Is/ = ( Tp.Ip +Ts.Is) / = 2AT / As Tp.Ip = Ts.Is = AT if we neglect magnetizing emf.
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AT = KW. AW . 2
Rating of 1 Transformer Rating of 1 Transformer in KVA Q = Vp.Ip.10-3 = Ep .Ip.10-3 = Et .Tp.Ip.10-3 = = Et KW.AW. 2 = 2.22 f But m KW.AW . x 10-3 AT .ET . 10-3 10-3 = 4.44 f m KW.AW . 2 x 10-3 ( Vp ED )
O/P Equation Voltage per turn Considering the output of one phase KVA rating of one phase.
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r. 10-3 4.44 f
Et = 4.44 f m = 4.44 f
r. 10+3 . 4.44
= k
As the ratio of m/AT depends upon type of transformer and therefore K is also a constant. Whole value depends upon type service condition and method of construction.
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Ratio of iron loss to copper loss Copper loss per m3 = p. 2 Pc = 2.1 x 10-3 8.9 x 103 Pi = Pi.Gi Ratio of iron to copper loss Pi Pc = Pi. Gi Pc. Gc 2 = 2.36 x10-3. 2 W/kg
Optimum Design Transformer may designed to make one of the following quantities minimum. i) Total Volume ii) Total weight iii) Total cost iv) Total losses
In general these requirements are contact directly and it is normally to satisfied to only one of them. All these quantity varies with ratio r = m / AT. If we chose the high value of r , then flux will become larger and consequently large core cross section is needed which result in higher volume, weight and cost of iron and gives higher iron loss.
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Design for minimum loss or Max. efficiency Total loss at full load = Pi + Pc At any Fraction x of full load, the total loss are Pi + x2 Pc If Q is the o/p of full load, the output of fraction load is Qx i.e. Efficiency at O/p xQ, X = xQ xQ + Pi + x2Pc This efficiency max. when Differentiating x we have d x = ( xQ + Pi + x2Pc ) Q xQ. ( Q + 2 x Pc) dx ( xQ + Pi + x2Pc )2 dx dx = 0
So that the mar. efficiency it obtained when the variable losses are equal to the constant losses.
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Ts
= Vs Et
The number of turn of an low voltage winding is usually determined in a preliminary design by adjusting the voltage / turn to get the number of l.v windg. Turn per phase Al an integer. T l.v
T l.v Et
= an integer
The number of h.v. wndg per turn per phase is T h.v = Vh.v Vl.v Note :- If the tapping are located in the middle part of an h.v. wndg, the no. of wndg. turn must be even to ensure the symmetry of winding. For a wndg. with tapping it is necessary to have a proper turn ratio or voltage ratio not only on the principal tapping but on the other taps us well. Therefore turns should be selected individually current in primary end. Therefore turns should be selected indiously current in primary winding Ip = KVA per Phase x 103 Vp .Tl.v
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The below table gives information about std. Stamping manufacture by precision pressing Division of M/s Guest Keen, Keen Williams for Small transformer and chokes. E I Stampings Sr. No. 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 No A 17 12 A 21 10 10 A 1 74 23 11 11 A 2 30 31 45 15 44 14 4 33 3 13 5/8 5/8 5/8 5/8 31/32 11/16 20 mm 7/8 1 1 1 1 1 28 mm 1.5/10 1.1/2 B 1.1/2 1.7/8 2 2.3/8 2.3/8 2.17/32 2.1/10 2.1/4 3 3 3 60 m 2.5/8 2.5/8 3 3 3.5/16 3.13/10 84 mm 3.3/4 4 C 1.1/4 1.9/10 2.1/8 2.1/8 2.1/8 2.1/4 1.32/32 1.7/8 2.1/4 2.5/8 3 50 mm 2.3/16 2.3/16 2.1/2 2.1/2 2,5/8 3.13/10 70 mm 3.1/8 3.1/2 D 5/16 5/16 3/8 3/8 3/16 11/32 3/8 3/8 3/8 3/8 10mm 7/16 7/16 17/32 17/32 14mm 5/8 E 5/16 3/8 3/8 3/8 5/16 11/32 3/8 3/8 3/8 3/8 10 m 7/16 7/16 14mm 5/8 Remark Dimensions
4 holer S/32 dia 4 4 4 4 4 4 4 4 holer S/32 dia hole 7/32 dia hole 7/32 dia hole 7/32 dia hole 7/32 dia hole 11/64 dia hole 7/32 dia hole 7/32 dia
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DESIGN
Single Phase Transformer The design of small low voltage transformer of rating 10 to 1000 VA is given. The saturation points of small transformer for design is the choice of turn per volt. Turns per Volt Sr.No 1. 10 2. 15 3. 20 VA Turn per Volt 23.3 17.5 14.0 Sr.No. 9 10 11 VA 200 250 300 Turn per Volt 3.5 2.8 2.8
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The frequency of Xmer is specified and the value of turms per volt Te is taken from above table. m is known. Net area of core Ai = m/Bm Bm = max. flux density = 1 wb/m 2 (Assum) Gross area of core Agi = Ai / 0.9
(stacting factor = 0.9). A shell type of construction is normally used for small transformer. The core is made up of any of the following combination of stampings.
E C D A D
E B
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Table E I Stamping with their dimension Sr. No. 1 Amp.current 5 A 1.1/2 B 4.3/4 C 3.3/4 D E 3.4 Remarks 4 holes 17/64 diam.
Winding Design :Current in primary winding (Ip) = VA/ The efficiency of small transformer varies from 80 to 96 percent. Area of Primary winding conductor Ap = Ip/ 8 mm 2 when p is the current density in primary winding conductor in A/mm 2. A value of 2.3 A/mm 2 may be used. Enammd round conductor are used for the windings of small transformer. Standard Size Sr.No. SWG Dim. mm Area mm2 1 24 (SWG) 0.559 (mm) 0.245 (mm2) Nominal cond. d/m 0.560 (mm) Overall diam. Max. Normal cover 0.614 (mm) Thick covering 0.681 (mm)
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Turns in primary winding = TP = VP. Te Current in Secondary winding cond. = Is = VA/v Area of sec. Winding cond. as = Is/s mm2. When calculating the number of secondary winding turns an allowance of 5 % extra turns is made to compesule for the voltage drop in the winding Ts = 1.05 Vs.Te. Material use in Transformer 1. Cu Conductor :- Copper conductor having 24 SWG is used for winding coated with insulation. 2. Stampings :- For making transformer E-I stamping is use for reducing the air gap 3. Rotating Switch :- It has 6 junction including Zero position. It is use for turn changing of transformer. 4. Two way switch :- This switch is use for measuring voltage in both I/P and O/P side. 5. One way switch :- This switch is use for O/P Supply. 6. 5 amp. Socket :- Here Socket is use for connecting the load terminal. 7. Neaon Indicator :- Neaon indicator is use for indicating the continuity of supply.
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BIBLIOGRAPHY
1) Electrical Machine Design
- A.K. Sawhney
2) Electrical Installation System
- M.P. Vader
3) Transformer
- BHEL
4) Machine and Transformer
- Deshmukh
5) Practical Transformer Design Handbook
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Voltmeter ( 0 300)