College of Engineering – Department of Mechanical Engineering

EE 422 DC AC MACHINERY

FINAL PROJECT

DISASSEMBLING
SECURE AUTOMATIC VOLTAGE
REGULATOR (AVR)
WITH A 500-WATT RATING

SUBMITTED BY:

GROUP NO. 3
CONTADO, PATRICK JHON G.
DIGMA, KURT ALDRIN M.
ENRIQUEZ, FRECILLE ANNE M.
ERESARI, JOSEPH BENEDICT
LANDICHO, LORIDEL M.
MANDAC, ARISTOTLE GEO M.
ME-2211

DRIZ, RHENZ ALDRIN D.

GARCIA, ELJAY JONAS T.
ME-2215

SUBMITTED TO:
ENGR. JOHN DARYL MAYO

MAY 2023
College of Engineering – Department of Mechanical Engineering

INTRODUCTION

The transformer is an electrical component that connects circuits of varying

voltages. This is commonly used in equipment that requires an alternating current
voltage converter to switch between circuits. When a transformer is used in an
alternating current circuit, the voltage and currents can be increased or decreased
based on the needs of the electrical equipment, device, or load. Transformers have
numerous applications. Power transformers are transformers with high power and
voltage ratings that can be used to increase or decrease voltage levels in power
generation, distribution, transmission, and utility. The three types of transformers that
are commonly used in electrical circuits are step-down transformers, step-up
transformers, and isolation transformers. In the context of an isolation transformer, the
voltage level remaining constant on both sides has no significance. There are several
types of transformers, including step-up and step-down transformers, power
transformers, single-phase transformers, three-phase transformers, and
autotransformers. In this experiment, we will disassemble a secure Automatic Voltage
Regulator Computer AVR with a 500-watt rating.

Additionally, Electrical4U (2021) stated that Transformers are used in almost all
electrical systems, from low to high voltage. Direct current (DC) does not generate
electromagnetic induction, it can only be used with alternating current (AC). The
alternating current voltage source injects alternating current into the transformer's
primary winding, which is how the single-phase transformer works. AC generates an
alternating electromagnetic field. The transformer's secondary circuit is formed by
magnetic field lines passing through the iron transformer core.

This experiment focuses on the dismantling and inspection of a transformer's

internal components. The main objective is to completely understand the design and
functionality of the transformer. Throughout the disassembly process, we will take
careful note of the orientation of the primary and secondary connections to ensure
proper reassembly and avoid any potential issues. Additionally, we will measure and
record the dimensions and specifications of the components to compare them with the
manufacturer's specifications. This will help us determine if the transformer is operating
within the expected parameters and identify any potential issues.

We aim to improve our understanding of transformer design and electrical

engineering through hands-on experimentation with internal components. This
knowledge will be crucial in ensuring the optimal functioning of transformers in a range
College of Engineering – Department of Mechanical Engineering

of electrical systems. Overall, this experiment is a great way to gain hands-on

experience and practical skills in electrical engineering by exploring the internal
components of a transformer, gaining insights into its design and operation, and
disassembling it in a safe and controlled environment.

DISCUSSION

This part focuses on giving a thorough knowledge of the Automatic Voltage

Regulator (AVR) and the theory and concepts that define how transformers operate.
The transformer equation, which creates a connection between primary and secondary
voltage, current, and turns ratio..

An AVR, in the context of engineering, stands for Automatic Voltage Regulator. It

refers to a device or system that is designed to automatically regulate and stabilize the
output voltage of an electrical power source. The primary function of an AVR is to
ensure that the voltage supplied to connected electrical devices or equipment remains
within specified limits, even in the presence of voltage fluctuations or varying load
conditions.

Automatic Voltage Regulators (AVRs) play a critical role in maintaining stable

voltage levels, ensuring a reliable and consistent power supply for various electrical
devices. In today's interconnected world, where electronics are integral to our daily
lives, the importance of AVRs cannot be overstated. These devices act as guardians,
protecting sensitive equipment from the harmful effects of voltage fluctuations and
ensuring optimal performance.

The primary function of an AVR is to regulate voltage levels by continuously

monitoring the input voltage and adjusting it to a desired output voltage within
predetermined limits. Voltage fluctuations, such as surges, sags, and spikes, can occur
due to factors like power grid instability, load variations, or environmental conditions.
AVRs act as a barrier between the power source and the connected equipment,
providing a stable voltage output that meets the specific requirements of the load. By
sensing and compensating for voltage variations, AVRs ensure that the voltage supplied
to the devices remains within safe operating limits. This mitigates the risk of electrical
failures, data loss, equipment breakdowns, and potential hazards to both individuals
and valuable assets.

Inside the AVR, there's a transformer that makes these functions operate.
Transformers can minimize losses while enhancing energy transfer. Magnetic flux can
College of Engineering – Department of Mechanical Engineering

be affected by the cross-sectional area of the core, the number of turns in the windings,
and the amount of current flowing through the windings. Understanding the behavior of
the magnetic flux is crucial for designing transformers that adhere to specific standards
for voltage transformation. A transformer is used to lower the voltage on the secondary
windings compared to the main windings.

Transformer Construction (Single-Phase)

Keep in mind that the two coil windings are just magnetically connected and
not electrically connected. When operating, a single-phase transformer can change
the voltage applied to the primary winding. A transformer is referred to as a step-up
transformer when it is used to "increase" the voltage on its secondary winding relative
to the primary. Step-down transformers are used to "decrease" the voltage on the
secondary winding relative to the primary.

There is a third scenario, though, in which the secondary voltage of a

transformer equals the main winding's applied voltage. In other words, the voltage,
current, and power delivered at its output are all the same. An Impedance
Transformer is the name given to a particular type of transformer that is mostly utilized
for impedance matching or the isolation of adjacent electrical circuits.

By altering the ratio of the primary winding (NP) coil turns to the secondary
winding (NS) coil turns, the voltage differential between the primary and secondary
windings may be produced.

Working Principle

From the ElectricTutorial (2023), Transformers are all about “ratios”. The ratio of
the primary to the secondary, the ratio of the input to the output, and the turns ratio of
College of Engineering – Department of Mechanical Engineering

any given transformer will be the same as its voltage ratio. In other words for a
transformer: “turns ratio = voltage ratio”.

It can be expressed also:

𝑉𝑝 𝑁𝑠 𝐼𝑝
𝑉𝑠
= 𝑁𝑝
= 𝐼𝑠
Since the transformer is essentially a linear device, there is now a ratio
between the main coil's number of turns and the secondary coil's number of turns.
This ratio, often known as the "turns ratio" (TR) of a transformer, is referred to as the
ratio of transformation. This turns ratio number controls how the transformer operates
and what voltage is available on the secondary winding.

Why are Automatic Voltage Regulators (AVR) important?

Unregulated generators, or generators without an automated voltage regulator

(AVR), typically fall short of providing enough power to run all of the associated
equipment and devices. This is due to the fact that some unregulated generators are
unable to regulate or manage voltage, hence the terminal voltage will constantly
decline as the load needs grow.

The performance of a generator as a whole may suffer if the voltage is not

maintained at a fixed, consistent rate, and any appliances, machines, or other items
that are powered by the generator may also suffer from the unregulated generator's
negative effects.

The automatic voltage regulator (AVR), which ensures that the voltage output
delivered will be consistent in its load current even if fluctuations were to occur in the
background, directly correlates to the performance and longevity of your generator as
well as the items that the generator is providing power to. This lessens and often even
completely prevents harm that any oscillations may bring about to equipment,
machinery, gadgets, and appliances.

What occurs if an AVR in a generator malfunctions?

Your generator will stop being excited if the AVR malfunctions. The generator's
voltage will drop quickly as a result of this loss of excitation, and the generator should
shut down as a result of an under-voltage malfunction.
College of Engineering – Department of Mechanical Engineering

If your generator's under-voltage protection is not activated, it may continue to

operate, endangering your equipment seriously.

MATERIALS

The disassembling process of an Automatic Voltage Regulator (AVR) involves

the use of plies, hammer, scissor, and screwdriver. In this part, it also includes the parts
of the transformer and its purpose.

Parts of the Image Description

Transformer

1. Primary Winding The primary winding of a

transformer is crucial for its
operation. It is the winding
that has been linked to the
supply. The coil that
receives input voltage and
current is referred to as the
primary winding. How
much voltage may be
transported from the input
to the output side is
determined by the number
of turns in the primary
winding. Furthermore,
College of Engineering – Department of Mechanical Engineering

more turns result in a larger

output voltage, whereas
fewer turns result in a lower
output voltage.

1. Secondary The winding on which

Winding the load is connected is
known as the secondary
winding. The secondary
winding is responsible for
receiving electrical energy
from the primary winding
and transforming it to
usable voltage levels for a
variety of applications.
Additionally, the
transformer's voltage
output is regulated by the
number of turns in the
secondary winding.

2. Insulating Insulating materials are

Materials essential in transformers.
When the transformer is
turned on, it is responsible
for offering better
performance. Its primary
role is also to prevent
electrical current from
passing between various
parts of the transformer,
which might cause harm.
More crucially, the
durability and stability of a
transformer are strongly
dependent on the efficient
use of insulating materials.
College of Engineering – Department of Mechanical Engineering

3. Core Laminated One of the core losses

Sheets that impacts transformer
performance is eddy
current loss. As a result,
the primary function of core
laminated sheets is to
reduce energy losses due
to eddy currents and
increase transformer
efficiency.

4. Cover of a A transformer's cover

Transformer is necessary to protect the
inner components from the
environment, dust, or other
factors that may impair the
transformer's internal
components. Furthermore,
the cover helps to the
long-term sustainability and
effectiveness of the
transformer.

5. Spool/ The Spool/ Framework

Framework protects the wire coil. The
core around which the
transformer windings are
coiled is the spool. It is also
utilized to offer structural
support and to prevent
energy losses caused by
eddy currents.
College of Engineering – Department of Mechanical Engineering

6. Terminal The terminal is critical in

controlling voltage levels.
The transformer terminal is
an important component
that connects the
transformer to the electrical
circuit. It is in charge of
moving electrical energy
from one circuit to another
using conductors and
wires.

7. Socket Sockets are tiny electrical

boxes that include a power
plug as well as many
power outlet sockets. It
connects the transformer to
the power source, ensuring
a secure and stable
connection between the
two.

8. Cable The cable is responsible

for transmitting current and
voltage between the main
and secondary windings.
The quality of the cable
used in the transformer is
critical since it has a
significant impact on its
performance. Poor-quality
cable can cause power
losses, make connecting to
other devices difficult, and
harm the transformer itself.
College of Engineering – Department of Mechanical Engineering

9. Fuse The primary function of

the fuse is applied to the
primary of the transformer
and is used only to prevent
transformer rupture due to
short circuits.

10. Switch A switch is an electrical

device that may manually
open or close an electrical
circuit.

PROCEDURES

This is the procedure how to disassemble the transformer:

1. Prepare all the materials that can be used during disassembling the
transformer.
College of Engineering – Department of Mechanical Engineering

2. Removing the covers and winding from the form of the transformer.

First, we remove the cover of the transformer using the

screwdrivers. Next, after we remove the cover, we proceed to separate the
E-Laminated Core and I-Laminated Core using a hammer. After that, we
remove the insulating materials, then we proceed to disconnect all wires in
the terminal.

3. Counting the number of turns in two windings.

We start to remove the primary

winding and we proceed to count the
number of turns. Before we proceed to
remove the secondary winding, we
again remove insulating materials, then
we proceed to start removing and count
the number of turns also. After all of it,
we found out the total turns of both
windings.

4. Performing parameter calculations to evaluate the transformer's

properties.

In addition to disassembling the transformer, we will do parameter

calculations to determine its qualities. Calculations will be performed to
determine the transformer's turns ratio, voltage ratio, current ratio, power
ratio, and impedance ratio. These calculations will be performed using the
design requirements and measurements acquired from the experiment.
College of Engineering – Department of Mechanical Engineering

DATA AND RESULTS

Theoretical ideas and calculations were covered in this section. The information
used in this study was taken from the computer's Automatic Voltage Regulator (AVR),
and the findings from an examination of the project's constituent parts are displayed
below:

Input voltage (Vp) = 220 V

Output voltage (Vs) = 110 V
Rating = 500 W = 500VA
Primary coil (Np) = 210 turns
Secondary coil (Ns) = 1470 turns

Turns Ratio
The turns ratio is calculated by dividing the number of turns in the primary
coil and secondary coil. The number of turns in the primary coil is 210 and in the
secondary coil is 1470 so the turns ratio is 0.1428571429.

To solve for turns ratio = ( 𝑵𝒑 / 𝑵𝒔 )

= 210 𝑡𝑢𝑟𝑛𝑠 / 1470 𝑡𝑢𝑟𝑛𝑠
= 0.1428571429

Voltage Ratio
The voltage ratio is calculated by dividing the output voltage by the input
voltage. The value of the output voltage is 220V and 110V for the input voltage.
Calculating the resulting voltage ratio is 2V.

To solve for voltage ratio = ( 𝑽𝒑 / 𝑽𝒔 )

= 220 𝑉 / 110 𝑉
=2V

Current Ratio
The current ratio is calculated by dividing the primary current by the input
current. To solve the primary current given by dividing the rating by the input
voltage. The value of the rating is 500VA and the value of the input voltage is
220V, calculating results to 2.272727273A. To solve the secondary current given
by dividing the rating by the output voltage. The value of the rating is 500VA, and
the value of the input voltage is 110V, calculating results to 4.545454545A
College of Engineering – Department of Mechanical Engineering

To solve for current ratio = ( 𝑰𝒑 / 𝑰𝒔 )

Primary current (Ip) = 𝑅𝑎𝑡𝑖𝑛𝑔 𝐼𝑛𝑝𝑢𝑡 𝑉𝑜𝑙𝑡𝑎𝑔𝑒

= 500 𝑉𝐴 / 220 𝑉
= 2.272727273 A

Secondary current (Is) = 𝑅𝑎𝑡𝑖𝑛𝑔 𝑂𝑢𝑡𝑝𝑢𝑡 𝑉𝑜𝑙𝑡𝑎𝑔𝑒

= 500 𝑉𝐴 / 110 𝑉
= 4.545454545 A

By using the computed values of primary and secondary current, we can

determine the current ratio resulting in a value of 0.5A.

Current ratio = ( 𝐼𝑝 / 𝐼𝑠 )
= 2.272727273 𝐴 / 4.545454545 𝐴
= 0.5 A

Power Ratio
The power ratio is calculated by dividing the primary power by the
secondary power. To solve for the primary power given by multiplying the input
voltage by the primary current. The value of the input voltage is 220V and the
value of the primary current is 2.272727273A, calculating results to 500VA. To
solve for the secondary power given by multiplying the output voltage by the
secondary current. The value of the output voltage is 110V and the value of the
secondary current is 4.545454545A, calculating results to 500VA.

To solve for power ratio = ( 𝑷𝒑 / 𝑷𝒔 )

Primary power (Pp) = 220 V x 2.272727273 A

= 500VA

Secondary power (Ps) = 110 V x 4.545454545 A

= 500 VA

By using the computed values of the primary and secondary ratios, we

can determine the power ratio resulting in a value of 1W.

Power ratio = ( 𝑃𝑝 / 𝑃𝑠 ) = 500 𝑉𝐴 / 500 𝑉𝐴 = 1 W

College of Engineering – Department of Mechanical Engineering

Impedance Ratio
The impedance ratio is calculated by dividing the primary impedance by
the secondary impedance. To solve for the primary impedance given by dividing
the input voltage by the primary current. The value of the input voltage is 220V
and the value of the primary current is 2.272727273A, calculating results to
96.8V/A. To solve for the secondary impedance given by dividing the output
voltage by the secondary current. The value of the output voltage is 110V and the
value of the secondary current is 4.545454545A, calculating results to 24.2V/A.

To solve for impedance ratio = ( 𝒁𝒑 / 𝒁𝒔 )

Primary impedance (Zp) = 𝑽𝒑 / 𝑰𝒑

= 220 𝑉 / 2.272727273 𝐴
= 96.8V/A

Secondary impedance (Zs) = 𝑉𝑠/𝐼𝑠

= 110 𝑉 / 4.545454545 𝐴
= 24.2 A

By using the computed values of the primary and secondary impedance,

we can determine the impedance ratio resulting in a value of 4 Ω.

Impedance ratio = ( 𝑍𝑝 / 𝑍𝑠 )
= 96.8 / 24.2
=4Ω

Core Area

The core area is calculated by multiplying the length and width of the core.
The length of the core is 7.8 cm, and the width of the core is 4.2 cm, resulting in
a core area of 32.76 cm.
Core dimension
Length = 4.50 cm
Width = 3.00 cm
To solve for Core area:
CORE AREA = Length x Width
= 4.50 cm x 3.00 cm
2
= 13.5 𝑐𝑚
College of Engineering – Department of Mechanical Engineering

CONCLUSIONS

A transformer is disassembled by carefully separating each component and noting

its specifications and settings. By carefully dissecting the transformer, researchers can
gain knowledge about its design principles, manufacturing processes, and material
choices. This thorough analysis helps to assess the transformer's performance, identify
any potential issues or weaknesses, and suggest enhancements.

Transformers are crucial components in electrical power systems because they

allow for isolation, impedance matching, and voltage change. The transformer equation,
which connects the primary and secondary voltages, currents, and turns ratios, serves
as the foundation for how they operate. Transformers can step-up or step-down the
voltage on the secondary side relative to the primary side by varying the number of coil
turns in the primary and secondary windings. Therefore, an automatic voltage regulator
(AVR) with 500-Watt Rating is considered as a step up / down voltage transformer since
the power input and output are alternating, either its power input is larger than the
power output or vice versa.

We were able to calculate the turns ratio, voltage ratio, current ratio, power ratio,
and impedance ratio using the data that we had obtained. A ratio of 0.1428571429 turns
exists between the primary coil's 210 turns and the secondary coil's 1470 turns. The
voltage ratio according to the calculation is 2V. Given a rating of 200 VA and an input
voltage of 110 V, a current ratio of 0.5 A is obtained. Using the computed values for the
primary and secondary ratios that are both 500 VA, 1W are the findings for the power
ratio. The impedance ratio comes last, it is computed by dividing primary impedance by
secondary impedance, and the result is 4 Ω .

For a number of reasons, it is essential to look at the theoretical basis of

transformers, including the transformer equation, operating concepts, core design, and
the function of magnetic flux. The first benefit is that it gives engineers a thorough
understanding of transformer behavior, enabling them to correctly forecast and evaluate
performance under various operating circumstances. Using this knowledge, engineers
can choose the right turns ratio and core design for the intended voltage transformation
and efficiency, which is essential for designing and improving transformers to fulfill
specific requirements.

Transformers can be designed to produce efficient and dependable power

distribution by carefully considering design parameters, material selection, and
College of Engineering – Department of Mechanical Engineering

optimization techniques. This enables the efficient use of electrical energy in a variety of
applications.

To sum up, it is crucial to comprehend the theoretical underpinnings of transformers

in order to construct, evaluate, optimize, and maintain transformers in power distribution
networks. It covers the knowledge and resources needed to comprehend transformer
behavior, manage voltage and power, improve core design, spot flaws, and assure
reliable and safe operation. Such research ultimately improves the efficient and reliable
distribution, use, and transmission of electrical power.
College of Engineering – Department of Mechanical Engineering

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Agarwal, T. (2021, December 13). What is a Switch: Introduction and Explain

About Types of Switches. ElProCus - Electronic Projects for Engineering
Students. https://www.elprocus.com/switches-types-working/

Admin. (2020). Why transformer cores are made of thin laminated sheets?
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Kim, D. (2022, July 8). What Is An Automatic Voltage Regulator? | What is AVR?
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What is a generator AVR or Automatic Voltage Regulator? What does an AVR

do? How does it work? (2022b, May 10). Welland Power.
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College of Engineering – Department of Mechanical Engineering

work-#:~:text=An%20automatic%20voltage%20regulator%20(AVR,of%20the%20
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