Complex Engineering Problem (CEP) EE-311

Ayesha ShakeelAbdur Rehman Abdul Moeed Laksh Rathi

2020099 2020036 2020009 2020207
Abstract—The objective of this CEP was to design a • Delta-Delta
transformer that was not only efficient in terms of
performance, but also cost effective. This document The operations and calculations for three-phase
provides a brief introduction to transformers and also transformers are very similar to the calculations for
provides insight into their working principles and single-phase transformers, these are performed
applications. According to the problem statement we have phase by phase using the techniques used for single-
designed a step-down transformer, from 40V to 12V, with
90VA rating. phase transformers.
A. Construction of Transformer
I. INTRODUCTION TO THE CEP A basic transformer is usually divided into the
The aim of this project is to design a transformer of primary and secondary windings, the core, input
90VA rating that can step down the 40 V input to 12 V connections and the output connections.
output. We have: 1) Windings: There are mainly two types of coils:
• Calculated number of turns on primary and • Primary coil: Connected to the AC Voltage
secondary windings based on the assumed supply(40v in our case).
window area. • Secondary coil: Used to transfer the energy
• Calculated the wire gauge for both the windings generated due to the magnetic flux.
and the impact of transformer rating on the wire 2) Core: The core provides a path for the magnetic
gauge. flux to flow. The core consists of assembly of sliced
• Calculated the total area of the core, and laminated sheets, rather than a solid block of iron.
selected the most feasible and appropriate size This helps reduce the eddy current losses. The core of
of the core for maximum flux. a transformer is of mainly two types:
All these calculations are aimed at keeping the • Shell Type: Windings surrounded by the
maximum mutual inductance and leakage inductance laminated core.
to an absolute minimum.

II. INTRODUCTION TO TRANSFORMERS

A transformer is a static electrical device more
commonly used in electrical circuits to step up (step
up) or step down (step down) a voltage level to
provide an output voltage according to requirements.
These electromagnetic devices use the principle of
electromagnetic induction to convert alternating Fig. 1. Shell Type, and core type Single Phase.
current at one voltage end into another alternating
current and voltage while keeping the frequency • Core Type: Winding wound on a laminated
value constant. core.
Transformers are usually divided into two types.
Single-phase and three-phase transformers. Single- Both types have advantages and disadvantages,
phase is for domestic use and three-phase is for the shell type has been found to be more
commercial use. A three-phase transformer consists efficient in terms of losses, but unfortunately
of three transformers, separated or combined in one due to its higher cost, the core type transformer
core. The primary and secondary coils can be is more commonly used.
connected in either a
delta connection or a wye(Y) connection Types of Transformer
independently. The possible connections are: • Conventional Transformer
• Wye-wye • Power Transformer
• Wye-Delta • Distribution Transformer
• Delta-Wye
 • Autotransformer: Both the windings are Fig. 3. Leakage and Mutual Fluxes in a Transformer core.
electrically connected unlike the other
transformers which has both the windings
B. Losses in a real transformer
separately wounded around the core(linked
magnetically). Along with the leakage of flux in either the primary
side or secondary side of the transformer there are
hysteresis, eddy current, and copper losses. These
effects are represented in the equivalent circuit of
the transformer and the imperfections can be
measured by the voltage regulation and efficiency of
• Isolation Transformer a real transformer.
• Instrument Transformer
• Current Transformer
• Potential Transformer

III. WORKING PRINCIPLE OF TRANSFORMERS IV.

The transformer consists of two windings, primary US
ES
coil, connected to the AC input supply, and secondary
OF
coil, connected to output , used to draw energy.
TR
These windings are wraped around a core which is AN
insulated and laminated, to reduce losses. The core of SF
the transformer provides a path for the current- OR
induced magnetic flux to flow through the coils or ME
windings. The mutual induction between the RS
between the windings of the transformer allow the
electrical energy to be transferred between the Transformers are used for many purposes. They
circuits. The transformer principle depends mainly on are mainly used to lower the voltage of common
two physical phenomena: circuits for daily use and to raise the voltage level for
• The current flowing through the wires creating a long distance transmission. Besides distribution
magnetic field purposes, it can also be used as an impedance
• Electric Induction transformation device, electrically separating two
As given by Faraday’s Law, when voltage is applied at circuits to prevent direct current from flowing
the primary side, a flux is produced. Change in flux through the circuit.
induces a voltage at the secondary coil; due to the
V. DESIGNING OF TRANSFORMER
high permeability of the core the net magnetomotive
force required in the core to produce its own field is In order to design a transformer main key features
very small. This results in the magnetomotive force at should be kept in mind namely the efficiency and
the primary side being approximately equal and cost. To design a transformer we need the following
opposite to that on the secondary side; this yields the calculations:
current ratio. • Area of cross-section

There are two types of flux induced on the primary • Number of primary turns

coil: • Number of secondary turns

mutual flux and a small amount of leakage flux. • Diameter of primary conductor
• Diameter of secondary conductor
A. Flux Density
Magnetic flux density is defined as magnetic flux A. Assumptions made
passing through a fixed area perpendicular to the Assumptions to be made:
field B. • Efficiency of the transformer is 80%.
• Magnetic flux density is assumed to be 1 to 1.2
(1)
Wb/mm2
• Magnetic field intensity =500 A/m
B. Values
Power Rating= 90 VA
Primary Voltage= 40 V
Secondary Voltage= 12 V
C. Calculating Primary and Secondary Currents

Primary Current = Power/Primary Voltage

Task 2( calculations )
Primary Current= 90/40 = 2.25 A
Secondary Current = Power/Secondary Voltage SILICONE STEEL

Secondary Current= 7.5A

D. Design of Core Magnetic field intensity of H at knee
The main step while designing the transformer is point ¿ 0.5 ×103 A/m
to calculate the core area.
Magnetic flux density B=1.2T

core area=1.52× √ 90=10.92 cm =1,693 inch The permeance is calculated as

2 2

Rounding off and considering the closest sizes

available we chose 1.5 inch bobbin.
β 1.2
An iron shell type core is used in this transformer as it =µ= =2.4 ×10−3
is more efficient i.e. it produces less losses in H 500
comparison to other materials and core types. This
core is also laminated in order to minimize the
leakage flux.
E. Design of Wire Gauge
In order to choose the appropriate wire gauge, the The reluctance of core is calculated as follows ,
following points should be considered:
• Working time of the transformer
1
• Installation Place Req =
1 1 1
Turns per Volt = 7.5/( 1.5x1.5)=3.33 + +
R1 R2 R3
Number of turns at primary side= 40x3.33 = 133.2
≈ 135 lC
R=
Area of primary conductor = 19SWG (using swg µA
tables available on internet, reference[2])

Number of turns at secondary side= 12×1.07 = 12.84

Req =14541
≈ 13
The magnetomotive force and flux is then calculated
using
Area of secondary conductor = 14 SWG

F=¿=ØR
F. Current Rating vs Conductor size Current
density (j) is assumed to be 2.3 Wb/mm2
Ø=0.020889
 Ø
β¿
A

here the calculated magnetic field intensity

H=Ø/µ=5996

In similar way we did calculations for iron core and

cobalt-iron alloy. After the
windings have been made on the bobbin ,the
laminated sheets of core are now inserted in the
H iron=5982.6A/m
bobbin. The sheets are of shapes `E’ and `I’ .the E
shaped sheets are added from alternate sides of
Hcobalt_iron=5995 A/m bobbin and then after bobbin is full of E sheets the I
part is inserted to cover up the air gaps. after that the
sheets are fastened together using bolts cable ties or
CONSTRUCTION OF TRANSFORMER metal pieces etc.

VI. CONCLUSION
We have used the values provided in the problem
statement to calculate desired values in order to
construct the core and the windings for the
transformer.
A laminated silicone steel core is chosen for this
transformer as silicone steel has higher permeability,
hence a better path for the magnetic flux to flow. The
The windings of the transformer are made keeping in lamination helps reduce the eddy current which due
mind the insulation requirement of the nature of to the induced voltage in the core results in heat
transformer and the size of the transformer. ideally losses.
the low voltage windings are made near the core and A shell type core is used as it provides a better
high voltage windings are made on top of that so the efficiency by controlling the leakage flux to some
insulation requirement for the windings is extent.
lower. .insulation was placed between the two REFERENCES
windings using turns of paper tape and dotted paper. [1] https://www.youtube.com/watch?v=khKSuq8gcKU
[2] https://www.electrical4u.net/transformer/swg-to-current-
amperage-chart-transformer-wire-amperage-table/
[3] https://www.britannica.com/technology/transformer-
electronics
[4] https://www.electronicshub.org/introduction-to-
transformers/
[5] https://www.researchgate.net/
[6] https://www.electricaltechnology.org/2012/02/uses-and-
application-oftransformer