EE-313 CEP

Single Phase Transformer Design

Mustafa Anique Ansari Salman Waheed Shaheer Ahmad Syed Asfandyar
2019415 2019451 2019465 2019489
FEE-B29 FEE-B29 FEE-B29 FEE-B29

Abstract—This paper articulates the prototyping of small scale,

single phase transformer from its perception to physical execu-
tion. Making use of alternating supply single phase transformers
are essential in linear power supply by stepping up/down inputs
from a domestic AC source. This particular design offers step
down functionality, 220/12 Volts, with 1 KVA power rating.
Postulates of operation and other parameters crucial to the
prototype formation are presented.

I. I NTRODUCTION

Human race is meant to advance in ways one can only

imagine. Since the inception of industrial revolution in the
18th century the rate of technological advancements has risen
exponentially. Introduction of the Alternating Current system
by Nikola Tesla caused efficient transmission and utilization of
electrical energy worldwide. AC system alongside the advent
of transformers in 1886 offered a multitude of opportunities
across a variety of fields including both residential and
commercial domains.
Transformers work primarily on Faraday’s Law of Fig. 1. 1-φ Transformer
Electromagnetic Induction. In layman’s term a transformer
is a device with two conductors (wires) wound around a
II. P RINCIPLE OF O PERATION
core (preferably iron core) with high magnetic permeability.
Input on one side, in accordance with the design, produces
an output of low or high magnitude on the other side. The working of a transformer boils down to the Faraday’s
Transformers are now available in numerous shapes and sizes. Law of Electromagnetic Induction. Put simply, Faraday’s Law
Step up/down, power transformer, distribution transformers, explains how current produces a magnetic field and conversely
instrument transformer and three phase transformer are some how a varying magnetic field produces an electric current
types of transformers. Common applications include high (Voltage). In terms of a transformer’s working, provided with
voltage transmission for reduced losses, impedance matching an AC input the primary coil produces a magnetic field. Due
of source and load, linear power supply at reduced voltage to the oscillating nature of the input an alternating voltage is
from traditional power circuits for operation of low voltage induced on the secondary winding as the conductor interacts
devices. with the changing field. The magnitude of this output may be
In this paper, we propose a single phase transformer altered by modifying the ratio of turns in the primary side to
specifically designed to provide a stable power supply, the turns of the secondary winding.
stepped down from a domestic source of 220 volts to 12 The relation amongst voltage, number of turns and current is
volts. During the drafting process we faced challenges such determined as:
as core selection, type of winding, turn ratio and wire gauge
selection. All choices were made whilst keeping in mind Vp Np Is
= =
efficiency, availability of materials and high quality to cost Vs Ns Ip
ratio.
 III. C ORE S ELECTION alternating voltage supply.
This friction between molecules causes heat to be developed
Core is a fundamental component that provides path to which, is an energy loss in the transformer’s core. This energy
magnetic flux. Air or vacuum provides a relatively week path, loss can overtime, shorten the life of the insulation material
for a given magnetic field strength H, whereas core made of used in the windings of the transformer.
iron forms 1500 times stronger induction field B. Hysteresis curve is shown below. Smaller the curve area,
In a shell type core for single phase, both primary and smaller will be the hysteresis losses and vice versa.
secondary windings are done on the same central limb. This
is done to maximize the induced mutual flux.
For shell type transformers, different types of cores are
available, out of which E-I and E-E core most common
commercially. Hence, in this project, laminated E-I core is
selected. Both E-I and E-E core types are shown in figure
below.
E-I laminated cores are more effective because more

Fig. 3. Eddy Current Losses

Fig. 2. Shell-Type Lamination

surface area is protected by winding. E-I cores are flat

stampings with no bending, cheap to manufacture and thus
easily available.Despite meticulous designing, losses are
encountered.
Practically, two types of core losses are produced, when
magnetic flux flows through the core, eddy current losses and
Fig. 4. B-H Curve
hysteresis losses.

• Eddy current losses IV. M UTUAL F LUX

Eddy Current are the product of Lenz’s Law. Instead of
solid iron core (single piece), thin strips of laminated cores
are used in transformer, since lamination is not designed to
provide path to any currents. This is because of the loop
that experiences a changing magnetic field. This will have
a considerable current flowing to each loop which is known
as eddy current. However, in a transformer, eddy currents
cannot be fully eliminated but can be decreased significantly
by laminated soft iron core instead of one solid core.
• Hysteresis losses
Hysteresis Losses in a transformer are caused because of
the friction of molecules against the flow of the magnetic
force required to magnetise the core. These lines of force are
constantly changing in magnitude and direction due to the
In a transformer, both Ip and Is produce magnetic flux
denoted by φ. The flux which links both the windings is
mutual flux.
In shell-type construction, iron surrounds both the windings.
Therefore, the flux produced by the winding tends to follow
the least-reluctive iron-path around them, rather than the high
reluctance air path.
In order to maximize mutual flux, we have selected shell
type core. This is done to maximize the induced mutual
flux. However, a small percentage of the flux produced by
windings flows outside of the core and is lost in air which is
a high reluctance path, and this is called leakage flux. This
leakage flux is of no use.
Shell type transformer core is a great choice to minimize
leakage flux since both windings are wound on the same • Turns/Volt:
limb. This center limb has two times the area of cross-section 7.5
Te = (4)
than the outer limbs. This provides two closed magnetic paths BobbinArea
for the flux to flow around the coil. = 7.5 /(2*2.5)
Mutual flux in a transformer can also be increased by winding = 1.5 Turns/V
secondary and primary coils one over each other. This type
of winding is called layered winding. • Primary Turns (Np):
Np = V p ∗ Te (5)
V. M ODELLING OF T RANSFROMER = 220*1.5
The windings of transformer have some resistances, which = 330 Turns
are modelled as resistors (Rp andRs ).
• Secondary Turns (Ns):
Alternating current in the windings causes self-inductance(L),
which are modelled as (Xp andXs ). Ns = V s ∗ Te (6)
The previously mentioned hysterisis and Eddy current losses
are both heat based losses in the core and can be modelled as = 12*1.5
Resitance(Rc ). = 18 Turns
The magnetization current lags behind the applied input volt- Wire Selection:
age by 90◦ , hence, it can be modelled as inductance(Xm ).
• Primary Side:
For current capacity of 4.55A,
Standard Wire Guage(SWG) of 18 must be used. Which has
following characteristics:
Diameter = 1.22mm
Mass per Length = 0.0104 kg/m
Resistance per length = 48.5 ohm/km
• Secondary Side:
For current capacity of 83.33A,
Standard Wire Guage(SWG) of 5 must be used. Which has
following characteristics:
Fig. 5. Equivalent Circuit of Transfromer Diameter = 5.38mm
Mass per Length = 0.203 kg/m
VI. C ALCULATIONS Resistance per length = 2.48 ohm/km
• Given Data:
Rated Power(S) = 1kVA
Turn Ratio = 220/12V
frequency = 50Hz
• Primary Current:
S 1000
Ip = = = 4.55A (1)
Vp 220
• Secondary Current:
S 1000
Is = = = 83.33A (2)
Vs 12
• For Bobbin Area: √
2
1000
Area = = 5.65inch2 (3)
5.6
• Commercially Available Bobbin Size:
Length = 2”
Width = 2.5” Fig. 6. Current Rating vs. Conductor Size Graph
Wire Quantity:
Bobbin Parameter = 2*(2+2.5) = 9”
• Primary Side:
Np*9 = 330*9 = 2970” = 75.44m
Wire used = 78m
• Secondary Side:
Ns*9 = 18*9 = 162” = 4.11m
Wire used = 5m

Wire Weight:

• Primary Side:
Weight = 0.0104*78 = 0.811kg
• Secondary Side:
Weight = 0.203*5 = 1.015kg

Copper Losses:

P = I 2R (7)
At rated current, copper losses are given as:
• Primary Winding:
P = 4.552 *(48.5*78*10−3 )
= 78.3 W
• Secondary Winding:
Fig. 7. Core Dimensions
P = 83.332 *(2.48*5*10−3 )
= 86.1 W
[8] https://www.quora.com/What-is-mutual-flux

Area of Core:

CoreArea = T otalArea − W indowArea (8)

= (6*5)-(2*1*3)
= 24 inch2

R EFERENCES
[1] Transformer Construction and Transformer Core Design (electronics-
tutorials.ws)
[2] Calculations for Design Parameters of Transformer - Engineer Experi-
ences
[3] Engineering Tables/Standard Wire Gauge - Wikibooks, open books for
an open world
[4] Transformer design PDF
[5] https://www.electronics-tutorials.ws/transformer/transformer-
construction.html
[6] https://circuitglobe.com/difference-between-core-type-and-shell-type-
transformer.html
[7] https://talema.com/introduction-to-transformers-standard-e-i-
construction/