MODULE 3
• Single phase transformers - working principle -
classification based on core- emf equation
transformation ratio
• Special purpose transformers- auto transformer-
working- welding transformer – construction -working
• Electric heating-Basic principle -modes of heat
transfer- methods of electric heating – induction
heating-dielectric heating (principle of operation
only).
• Electric furnaces- working- induction and arc
furnaces-applications
Transformers
• P=vi *pf
• For a constant power, if v is increases, i will
decrease
• P= i^2 R loss will decrease
• To overcome losses, generated electricity is
passed through step up transformer and
passed to transmission system. It is stepped
down at distribution side.
Transformers
• The single-phase transformer works on the principle
of Faraday’s Law of Electromagnetic Induction.
● It is a static device that transfers electric power in
one circuit to another circuit of the same frequency.
● It consists of primary and secondary windings.
● When the primary of a transformer is connected to
an AC supply, the current flows in the coil and the
magnetic field build-up.
● An alternating flux is produced in the core by the AC
primary current.
● The alternating flux gets linked with the secondary
winding through the core.
● According to Faraday’s laws of electromagnetic
induction this varying flux will induce voltage into the
secondary winding.
It produces a self induced emf E1 in primary winding and mutually
induced emf E2 in secondary winding
Transformation ratio
• A transformer consists of two sets of coils,
insulated from each other.
• One of the coils called the primary coil has Np
turns. The other coil is called the secondary
coil; it has Ns turns.
Classification based on core
• Windings are wrapped around two sides of a laminated square core.
AUTO TRANSFORMER
➔ In an autotransformer,
one single winding is used
as primary winding as well
as
secondary winding.
➔ The winding AB of total
turns N1 is considered as
primary winding.
➔ This winding is tapped
from point ′C′ and the
portion BC is considered as
secondary.
➔ If V1 voltage is applied
across the primary winding
the voltage across the
Advantages:
• i. Smaller in size
• [Link] less copper
• [Link] efficient
Welding transformer
Low initial cost
Low operation and
maintenance cost
Voltage drop is less
Welding transformer
• Welding transformer is a step down transformer which
reduces the voltage from the source voltage to a lower
voltage that is suitable for welding.
• The secondary may have several taps for adjusting the
secondary voltage to control the welding current.
• One end of the secondary is connected to the welding
electrode, whereas the other end is connected to the
pieces to be welded .
• If any high current flows, heat is produced due to the
contact resistance between the electrode and the pieces
to be welded.
• The generated heat melts a trip of the electrode and the
gap between the two pieces is filled.
Electric heating
• Principle of heat production from electric
power:
• Joules law of heating- The heat generated
due to the current flow in an electric wire is
proportional to the product of resistance of
the wire, time of flow and square of the
current passed.
• By Joules law, Electric heat =
• where I-current ,R-resistance of the element,t-
time during which current is passed
Methods of electric heating
Induction heating
• The process of heating an electrically conducting object (usually a metal)
by electromagnetic induction, through heat generated in the object
by eddy currents.
• An induction heater consists of an electromagnet and an electronic
oscillator that passes a high-frequency alternating current (AC) through
the electromagnet.
• The rapidly alternating magnetic field penetrates the object,
generating electric currents inside the conductor, called eddy currents.
• The eddy currents flowing through the resistance of the material heat it
by Joule heating. (I^2 *R)
• In ferromagnetic materials like iron, heat may also be generated by
magnetic hysteresis losses.
• The frequency of current used depends on the object size, material type,
coupling (between the work coil and the object to be heated) and the
penetration depth.
Induction heating advantages:
• Improved process efficiency
• Localized, constant and precise heating
• Temperature control
• Energy saving
• Possibility of integration into production lines
• Best quality and performance
• Pollution free, fast and secure technology
• Improved working environment
Dielectric heating
• The process of heating up material by causing dielectric
motion in its molecules using alternating electric fields’.
• Polar molecules contain electric dipole moments. When
such molecules are exposed to the electric field, they
try to align themselves in the direction of the field.
• When the applied field oscillates, these molecules of
the material undergo rotations in order to keep
themselves aligned with the field.
• When the field changes direction, these molecules also
reverse their direction. This process is called “Dielectric
Rotation”
• ‘As the field alternates, the molecules reverse direction.
Rotating molecules push, pull, and collide with other
molecules (through electrical forces), distributing the
energy to adjacent molecules and atoms in the
material. The process of energy transfer from the
source to the sample is a form of radiative heating.
• The temperature of the molecules is related to the
kinetic energy of the molecules. In the dielectric
rotation of the molecules, as the kinetic energy of the
molecules increases, the temperature of the molecules
increases. When the molecules collide or come in
contact with other molecules, this energy gets
transferred to all parts of the material thus heating up
the material.
Dielectric heating applications
• Food Processing- Dehydrating, Cooking, Defrosting
• Preheating of Plastic Preforms
• Gluing of Wood- better adhesion
• Baking of Foundry Cores-metal castings
• Diathermy-heating tissues and bones of the body
required for the treatment of certain disease
• Sterilization-bandages, absorbent cotton, sterile
gauge, instrument
• Textile Industry-drying
• Induction furnace is used to melt metal alloys which
melt at high temperature.
• Induction furnace works based on the principle of
induction heating
• It consists of crucible. Inside of this crucible is coated
by refractory material to resist flow of heat from inside
to outside. The material to be heated (also called
charge) is collected in the crucible. This crucible is
surrounded by water cooled primary copper coils which
is connected to high frequency AC supply.
• • When AC supply is given to copper coils, it produces
alternating magnetic field. It induces eddy currents in
the charge. Due to the flow of eddy current in the
charge, heating of charge takes place and it melts.
Core type induction furnace
Core type induction furnace
• It is essentially a transformer in which the charge to be
heated forms a single-turn short-circuited secondary
and is magnetically coupled to the primary by an iron
core.
• The furnace consists of a circular hearth which contains
the charge to be melted in the form of an annular ring.
• When there is no molten metal in the ring, the
secondary becomes open-circuited there-by cutting off
the secondary current.
• Hence, to start the furnace, molten metal has to be
poured in the annular hearth.
Coreless induction furnace
Coreless induction furnace
• There is no core and thus the flux density will be low.
• Hence for compensating the low flux density, the
current supplied to the primary should have
sufficiently high frequency.
• The flux set up by the primary winding produces eddy
currents in the charge. The heating effect of the eddy
currents melts the charge.
• Stirring of the metals takes place by the action of the
electromagnetic forces
• The container acts as secondary winding
arc furnace 3phase
It consists of steel shell with refractory clay lining. It has a hearth
with silica lining, walls and roof.
The electric current is delivered through electrodes inserted into
furnace.
The material to be melted is known as charge
It is fed through charging door. Electrodes are lowered until arc is
struck.
The metal is melted gradually and impurities are removed.
used in larger foundries and mini-mill steelmaking operations
