Submitted to-

Prof.Dr.Md.Habibullah
Design of Asst.Prof.Abu Syed Md. Jannatul
Islam

Single-phase Shell-Type Dept. of Electrical and Electronic

Engineering,KUET

Transformer

Submitted by-
Tushar Ahammed 1903055
Md. Solayman 1903056
MD Abdur Rahman Akash 1903057
Parmith Utsho 1903058
Tridib Chakrabortty Prapya
1903059
Tamanna Tanvin Tanha 1903060
Objectives
To understand the details of a transformer.
Practical knowledge about different operation and
winding types
of a transformer.
To design a transformer with the given requirement.
To testify the turns ratio and voltage requirements.
To observe the transformer under open circuit and
short circuit test

2
Transformers
Introduction:
A transformer is a passive component that transfers electrical
energy from one electrical circuit to another circuit, or multiple
circuits, without changing the frequency. Transformer can
increase or decrease the voltage with
corresponding decrease or increase in current.

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Transformers
Types of transformers:
Transformers can be classified on different basis, like types
of construction, types of cooling etc.

On the basis of construction, transformers can be classified

into two types as:

(i) Core type transformer

(ii) Shell type transformer

Core Type Shell Type 4

Transformers
(i) Core Type Transformer:
In core type construction of the transformer, the magnetic core consists of
two vertical lags called limbs and two horizontal sections called yokes. In
order to reduce the leakage flux to its minimum value, half of each
winding is placed on each lag of the core (as shown in previous slide). The
low voltage (lv) winding is placed next to the core and the high voltage
(hv) winding is placed around the low voltage winding.

(ii) Shell Type Transformer:

In the shell type construction of the transformer, the magnetic core
consists of three vertical lags and two horizontal sections. Both the
primary and secondary windings are wound on the central limb and the
two outer limbs provide the low reluctance flux path (shown in previous
slide).

5
Question:
Design a 46 VA, 220V/24 V, 50 Hz, single phase, shell type,
and crossover winding based transformer. Transformer
efficiency of 90% and voltage drop at secondary side is not
more than 5%.

Core of Shell Type

Transformer
‘E’ and ‘I’ shaped laminated
segments are used to make
the core of the shell-type
transformer
6
Steps of designing a transformer

1.Sizing of Core 2.Calculation of winding 3. Winding Overall Dimensions

#Column Width #Number of Wire Turns/Layer*

#Dimensions of Reel #Voltage/Turn and Current*
#Net Thickness of
#Number of Wire Layers*
#Number of Turns*
Iron Package #Radial Dimension of Winding
#Selection of Wire Available in
#Number of
Commercial Diameter*
Laminations

*for both primary and

secondary 7
Input Data of Designed Transformer

Construction : Single-Phase Shell-Type,Crossover

Winding based Transformer

Apparent 46VA
Power :

Voltage Rating : 220V/24V,50hz

Consider efficiency of 90% and

Voltage drop in secondary isn’t more
than 5%.

8
Sizing of core
The core was given
15
90 • Column Width: 30 mm
30
• Dimension of Reel:
15
12mm×42mm
15 45

9
Calculation of winding
Given ,

Apparent power =46VA

Determine the flux: Ø =
Considering utilization
coefficient,Ku = 2.55*10-2 =7.74*10-4 wb

Voltage per unit turn =4.44*f* Ø =0.171v

#For Shell single-phase High side turns,N220v =220/0.172=1280

utilization coefficient,

Ku =(2.5-4)*10-2 Low side turns,N24v =(24+1.2)/0.172 =147

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Winding overall dimensions
For High side,assuming 80% Diameter,D220v=0.31mm
efficiency,
The number of turns per layer =
Current ,I220v =46VA/(220*0.8) h/1.05*0.31=125
( the filling coefficient=1.05)
=0.2614A

For Intermittent operation,

Current density = 3.5A/mm2

Cross section area ,A220v The number of layers,S220= N220/n220 =11

=0.2614A/(3.5A/mm2)
=0.075mm2
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Winding overall dimensions
For Low side, Commercial diameter,
Ø24v=0.84mm
Current,I24v =46VA/24V =1.92A
The number of turns per layer,
For Intermittent operation,
Current density = 3.5A/mm2 n24v=h/1.05*Ø24v =47

Cross section area ,A24v ( the filling coefficient=1.05)

=1.92A/(3.5A/mm2) =0.55mm2 The number of
Diameter,D24v=0.84mm layers,S24v=N24v/n24v =4

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Transformer Test
Under load condition
At High Voltage Side, At low Voltage Side,

Voltage ,V220v= 220V Voltage ,V24v= 23V

Current,I220v =0.22A Current,I24v =1.65A

Without load condition

At High Voltage Side, At low Voltage Side,
Voltage ,V220v= 220V Voltage ,V 24v= 23V

Turns Ratio = 9.56

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Calculation
Error = (46-37.95)/(46 ) x 100%
= 17.5 %

Voltage Drop=1-(23V/24V)
=0.04
=4.16%

Transformer Prototype

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Drawbacks
When the transformer was tested we found some error, the error
was 17.5% as we got VA at secondary side 37.5 instead of 46.
We are thinking the reason behind error is we used more than 65
laminations as we calculated for tightening the core and fill up
the air gap. Again we couldn’t use laminations between every
adjacent layers of primary winding because of our compact size
of reels.

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Thank you….

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