KHULNA UNIVERSITY OF ENGINEERING & TECHNOLOGY
Department of Electrical & Electronic Engineering
Course no: EE3220
Course Title: Electrical Machine Design.
Name of the Project: Single phase
Transformer Design(shell type)
Remarks:
Submitted by
Md. Jahirul Islam
Assistant Professor
Dept. of EEE, KUET, Khulna
Md. Tawabur Rahman
Lecturer
Submitted By
SL. no Name Roll
01 Monoara Begum 1903035
02 Md. Zahid Hossen 1903036
03 Nahid Al Mahmud 1903037
04 Masrima Bari Jitu 1903038
05 Selim Reza 1903039
06 Oyshi kar 1903040
07 Nafisa Pervin 1903041
Objectives:
To understand the details of a transformer.
To gain 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.
Introduction:
A transformer can be defined as a static device
which helps in the transformation of electric
power in one circuit to electric power of the same
frequency in another circuit. The voltage can be
raised or lowered in a circuit, but with a
proportional increase or decrease in the current
ratings.
The main principle of operation of a transformer is
mutual inductance between two circuits which is
linked by a common magnetic flux. A basic
transformer consists of two coils that are electrically
separate and inductive but are magnetically linked
through a path of reluctance. The working principle
of the transformer can be understood from the figure
below.
Transformer Working
As shown above the transformer has primary and
secondary windings. The core laminations are joined
in the form of strips in between the strips you can
see that there are some narrow gaps right through
the cross-section of the core. These staggered joints
are said to be ‘imbricated’. Both the coils have high
mutual inductance. A mutual electro-motive force is
induced in the transformer from the alternating flux
that is set up in the laminated core, due to the coil
that is connected to a source of alternating voltage.
Most of the alternating flux developed by this coil is
linked with the other coil and thus produces the
mutually induced electro-motive force. The so
produced electro-motive force can be explained with
the help of Faraday’s laws of Electromagnetic
Induction as
dI
e=M
dt
If the second coil circuit is closed, a current flows in
it and thus electrical energy is transferred
magnetically from the first to the second coil.
The alternating current supply is given to the first
coil and hence it can be called as the primary
winding. The energy is drawn out from the second
coil and thus can be called as the secondary winding.
In short, a transformer carries the operations shown
below:
1. Transfer of electric power from one circuit to another.
2. Transfer of electric power without any change in
frequency.
3. Transfer with the principle of electromagnetic
induction.
4. The two electrical circuits are linked by mutual
induction.
Transformer Construction
For the simple construction of a transformer, you
must need two coils having mutual inductance and a
laminated steel core. The two coils are insulated
from each other and from the steel core. The device
will also need some suitable container for the
assembled core and windings, a medium with which
the core and its windings from its container can be
insulated.
In order to insulate and to bring out the terminals of
the winding from the tank, apt bushings that are
made from either porcelain or capacitor type must be
used.
In all transformers that are used commercially, the
core is made out of transformer sheet steel
laminations assembled to provide a continuous
magnetic path with minimum of air-gap included.
The steel should have high permeability and low
hysteresis loss. For this to happen, the steel should
be made of high silicon content and must also be
heat treated. By effectively laminating the core, the
eddy-current losses can be reduced. The lamination
can be done with the help of a light coat of core plate
varnish or lay an oxide layer on the surface. For a
frequency of 50 Hertz, the thickness of the
lamination varies from 0.35mm to 0.5mm for a
frequency of 25 Hertz.
Types of Transformers
The types of transformers differ in the manner in
which the primary and secondary coils are provided
around the laminated steel core. According to the
design, transformers can be classified into two:
1.Core- Type Transformer
In core-type transformer, the windings are given to a
considerable part of the core. The coils used for this
transformer are form-wound and are of cylindrical
type. Such a type of transformer can be applicable for
small sized and large sized transformers. In the small
sized type, the core will be rectangular in shape and
the coils used are cylindrical. The figure below shows
the large sized type. You can see that the round or
cylindrical coils are wound in such a way as to fit
over a cruciform core section. In the case of circular
cylindrical coils, they have a fair advantage of having
good mechanical strength. The cylindrical coils will
have different layers and each layer will be insulated
from the other with the help of materials like paper,
cloth, micarta board and so on. The general
arrangement of the core-type transformer with
respect to the core is shown below. Both low-voltage
(LV) and high voltage (HV) windings are shown.
Core Type Transformer Cruciform Section
Core Type Transformers
The low voltage windings are placed nearer to the
core as it is the easiest to insulate. The effective core
area of the transformer can be reduced with the use
of laminations and insulation.
2.Shell-Type Transformer
In shell-type transformers the core surrounds a
considerable portion of the windings. The
comparison is shown in the figure below.
Core Type and Shell Type Transformer Winding
The coils are form-wound but are multi-layer disc type
usually wound in the form of pancakes. Paper is used to
insulate the different layers of the multi-layer discs. The
whole winding consists of discs stacked with insulation
spaces between the coils. These insulation spaces form
the horizontal cooling and insulating ducts. Such a
transformer may have the shape of a simple rectangle or
may also have a distributed form. Both designs are shown
in the figure below:
Shell Type Transformers Rectangular Form
Shell Type Transformers Distributed Form
A strong rigid mechanical bracing must be given to
the cores and coils of the transformers. This will
help in minimizing the movement of the device and
also prevents the device from getting any insulation
damage. A transformer with good bracing will not
produce any humming noise during its working and
will also reduce vibration.
A special housing platform must be provided for
transformers. Usually, the device is placed in tightly-
fitted sheet-metal tanks filled with special insulating
oil. This oil is needed to circulate through the device
and cool the coils. It is also responsible for
providing the additional insulation for the device
when it is left in the air.
There may be cases when the smooth tank surface
will not be able to provide the needed cooling area.
In such cases, the sides of the tank are corrugated or
assembled with radiators on the sides of the device.
The oil used for cooling purpose must be absolutely
free from alkalis, Sulphur and most importantly
moisture. Even a small amount of moistures in the
oil will cause a significant change in the insulating
property of the device, as it lessens the dielectric
strength of the oil to a great extent. Mathematically
speaking, the presence of about 8 parts of water in 1
million reduces the insulating quality of the oil to a
value that is not considered standard for use. Thus,
the tanks are protected by sealing them air-tight in
smaller units. When large transformers are used, the
air tight method is practically difficult to implement.
In such cases, chambers are provided for the oil to
expand and contract as its temperature increases and
decreases. These breathers form a barrier and resists
the atmospheric moisture from contact with oil.
Special care must also be taken to avoid sledging.
Sledging occurs when oil decomposes due to over
exposure to oxygen during heating. It results in the
formation of large deposits of dark and heavy matter
that clogs the cooling ducts in the transformer.
The quality, durability and handling of these
insulating materials decide the life of the
transformer. All the transformer leads are brought
out of their cases through suitable bushings. There
are many designs of these, their size and
construction depending on the voltage of the leads.
Porcelain bushings may be used to insulate the leads,
for transformers that are used in moderate voltages.
Oil-filled or capacitive-type bushings are used for
high voltage transformers.
The selection between the core and shell type is
made by comparing the cost because similar
characteristics can be obtained from both types.
Most manufacturers prefer to use shell-type
transformers for high-voltage applications or for
multi-winding design. When compared to a core
type, the shell type has a longer mean length of coil
turn. Other parameters that are compared for the
selection of transformer type are voltage rating, kilo-
volt ampere rating, weight, insulation stress, heat
distribution and so on.
Question: Design a 50 VA, 220V/5 V, 50 Hz, single phase,
shell type, and cylindrical winding
based transformer. Consider transformer efficiency of 80%
and voltage drop at secondary side is
not more than 1%.
Solution:
Assuming an utilization coefficient Ku = 2.55 ×10-2
, we can determine the flux:
Ø=Ku√kVA/f =2.55×10−2 √0.05/50 =0.81× 10−3 Wb
Therefore, when an induction B = 1.1 Wb/m-2
is fixed, it is possible to calculate the area of the
net iron section
Air=Ø
𝐵
=
0.81×10−3
1.1
=0.74*10−3 𝑚2=740 mm2
The column width is approximately
C=√𝑉𝐴 4
=√50 4
= 2.66 cm
Therefore a commercial lamination can be selected with
external size 100 x 120, column
size 40 x 60 and window size 20 x 60, having 0.5mm
thickness including the paint insulation.
The net thickness of the iron package is:
Lp=
Air
𝐶
=
740
30
= 25 mm
Assuming a packing coefficient Ks = 0.9 the gross
thickness is
Lpo=
Lp
𝐾𝑠
=
25
0.9
= 28 mm
corresponding to
28
0.5
= 56 laminations
To mount the core, the laminations are inserted into a 40 x
40 nylon reel (on which the winding
has been previously realized); the laminations are
alternatively inserted, so that the
joints are staggered.
The voltage per turn is
e = 4.44 f Ø = 4.44×50 ×0.81× 10−3 = 0.18V
The number of primary turns is therefore
N1=
V1
e
=
220
0.18
=1223
Assuming a voltage drop from no-load to load condition of
1%, the number of secondary
turns is
N2=
V2+dV
e
=
5+0.05
0.18
=29
Assuming a 80% efficiency, the primary current is
calculated
I1=
VA
V1∗n
=
50
220∗0.80
=0.284A
Assuming a current density of 3.5 A/mm2
, this corresponds to a copper section of
Acu1=
I1
𝐽
= 0.081 mm2
Therefore we can select the commercial diameter
Ø1 = 0.321mm
The secondary current is now calculated
I2=
VA
V2
=
50
5
= 10A
This corresponds to a copper section of
Acu1=
I2
𝐽
= 2.857 mm2
Therefore we can select the commercial diameter
Ø2 = 1.91 mm
Considering h= 40 mm , kr=1.05
n1=
h
Kr∗Ø1
=
40
1.05∗0.321
=119
n2=
h
Kr∗Ø2
=
40
1.05∗1.91
=20
The number of layers is therefore
Sp=
N1
n1
=
1223
119
=12
Ss=
N2
n2
=
29
20
=2
The radial dimensions of winding is
R = Sp Ø1 + Ss Ø2s+ paper thickness *(Sp + Ss -1) +
latheroid thickness • 2
=12*0.321+2*1.91+0.1*(12+2-1)+0.3*2 =9.57 mm
=10 mm
Result and Discussion :
