Design of transformers

 Introduction –
A transformer is defined as a passive electrical device that transfers electrical energy from one
circuit to another through the process of electromagnetic induction. It is most commonly used to increase
(‘step up’) or decrease (‘step down’) voltage levels between circuits. A transformer is a passive
component that transfers electrical energy from one electrical circuit to another circuit, or multiple
circuits. A varying current in any one coil of the transformer produces a varying magnetic flux in the
transformer's core, which induces a varying electromotive force across any other coils wound around the
same core. Electrical energy can be transferred between separate coils without a metallic (conductive)
connection between the two circuits. Faraday's law of induction, discovered in 1831, describes the
induced voltage effect in any coil due to a changing magnetic flux encircled by the coil.

Transformers are most commonly used for increasing low AC voltages at high current (a step-up
transformer) or decreasing high AC voltages at low current (a step-down transformer) in electric power
applications, and for coupling the stages of signal-processing circuits. Transformers can also be used for
isolation, where the voltage in equals the voltage out, with separate coils not electrically bonded to one
another. Since the invention of the first constant-potential transformer in 1885, transformers have
become essential for the transmission, distribution, and utilization of alternating current electric power.
A wide range of transformer designs is encountered in electronic and electric power applications.
Transformers range in size from RF transformers less than a cubic centimetre in volume, to units
weighing hundreds of tons used to interconnect the power grid.
  Transformer Theory –

Working principle of transformer -

The working principle of a transformer is very simple. Mutual induction between two or more
windings (also known as coils) allows for electrical energy to be transferred between circuits. This
principle is explained in further detail below.

Say you have one winding (also known as a coil) which is supplied by an alternating electrical
source. The alternating current through the winding produces a continually changing and alternating flux
that surrounds the winding.If another winding is brought close to this winding, some portion of this
alternating flux will link with the second winding. As this flux is continually changing in its amplitude
and direction, there must be a changing flux linkage in the second winding or coil. According to
Faraday’s law of electromagnetic induction, there will be an EMF induced in the second winding. If the
circuit of this secondary winding is closed, then a current will flow through it. This is the basic working
principle of a transformer.

Let us use electrical symbols to help visualize this. The winding which receives electrical power
from the source is known as the ‘primary winding’. In the diagram below this is the ‘First Coil’.

The winding which gives the desired output voltage due to mutual induction is commonly known
as the ‘secondary winding’. This is the ‘Second Coil’ in the diagram above. A transformer that increases
voltage between the primary to secondary windings is defined as a step-up transformer. Conversely, a
transformer that decreases voltage between the primary to secondary windings is defined as a step-down
transformer. Whether the transformer increases or decreases the voltage level depends on the relative
number of turns between the primary and secondary side of the transformer. If there are more turns on
the primary coil than the secondary coil than the voltage will decrease (step down).If there are less turns
on the primary coil than the secondary coil than the voltage will increase (step up).While the diagram of
the transformer above is theoretically possible in an ideal transformer – it is not very practical. This is
because in the open air only a very tiny portion of the flux produced from the first coil will link with the
second coil. So the current that flows through the closed circuit connected to the secondary winding will
be extremely small (and difficult to measure).The rate of change of flux linkage depends upon the
amount of linked flux with the second winding. So ideally almost all of the flux of primary winding
should link to the secondary winding. This is effectively and efficiently done by using a core type
transformer. This provides a low reluctance path common to both of the windings. The purpose of the
transformer core is to provide a low reluctance path, through which the maximum amount of flux
produced by the primary winding is passed through and linked with the secondary winding.

 Classification of transformers –

1) Position of the windings concerning the core

a. Core type
b. Shell type
2) According to the transformation ratio or number of turns in the windings
a. Step up
b. Step down
3) Types of services
a. Power transformer
b. Distribution transformer
c. Instrument transformer
i. Current transformer
ii. Potential transformer
iii. Auto-transformer
iv. Isolating transformer
d. Rotating transformer
4) On the basis of the supply
a. Single-phase
b. Three-phase
5) On the basis of cooling
a. Air Natural (AN)
b. Air Forced (AF)
c. Oil Natural Air Natural (ONAN)
d. Oil Natural Air Forced (ONAF)
e. Oil Forced Air Forced (OFAF)
f. Oil Natural Water Forced (ONWF)
g. Oil Forced Water Forced (OFWF
  Designing of transformer –
The Design Problem Generally -

The designer is faced with a set of constraints that must be observed in the design on any
transformer. One of these constraints is the output power, P0, (operating voltage multiplied by maximum
current demand). The secondary winding must be capable of delivering to the load within specified
regulation limits. Another constraint relates to the minimum efficiency of operation, which is dependent
upon the maximum power loss that can be allowed in the transformer. Still another defines the maximum
permissible temperature rise for the transformer when it is used in a specified temperature environment.
One of the basic steps in transformer design is the selection of proper core material. Magnetic materials
used to design low and high frequency transformers are shown in Table 7-1.

Each one of these materials has its own optimum point in the cost, size, frequency and
efficiency spectrum. The designer should be aware of the cost difference between silicon-iron, nickel-
iron, amorphous and ferrite materials. Other constraints relate to the volume occupied by the transformer
and, particularly in aerospace applications, the weight, since weight minimization is an important goal in
today's electronics. Finally, cost effectiveness is always an important consideration.

Depending upon the application, certain ones of these constraints will dominate. Parameters
affecting others may then be traded off as necessary to achieve the most desirable design. It is not
possible to optimize all parameters in a single design because of their interaction and interdependence.
For example, if volume and weight are of great significance, reductions in both can often be affected, by
operating the transformer at a higher frequency, but, at a penalty in efficiency. When the frequency
cannot be increased, reduction in weight and volume may still be possible by selecting a more efficient
core material, but, at the penalty of increased cost. Thus, judicious trade-offs must be affected to achieve
the design goals. Transformer designers have used various approaches in arriving at suitable designs. For
example, in many cases, a rule of thumb is used for dealing with current density. Typically, an
assumption is made that a good working level is 200 amps-per-cm2 (1000 circular mils-per-ampere).
Design of single phase transformer –
WINDOW DIMENSIONS
DESIGN OF YOKE

The entire core is divided into two portions. The vertical portion is called core or limb or leg. The
horizontal portion is called yoke.
OVERALL DIMENSIONS
OPERATING CHARACTERISTICS

REGULATION

NO LOAD CURRENT
 1. No load current of single phase transformer

KPK  Amplitude factor  2

No load current I0  Im  I2 2
l

2. No load current of three phase transformer

No load current I0  I2m  I 2

l

TEMPERATURE RISE IN TRANSFORMERS

TRANSFORMER OIL AS A COOLING MEDIUM
DESIGN OF TANK AND COOLING TUBES OF TRANSFORMER
COOLING OF TRANSFORMERS

METHODS OF COOLING OF TRANSFORMERS

CONCLUSION