Khulna University of

Engineering and Technology

Department of Electrical and Electronic
Engineering

Course Title: Electrical Machine Design

Course No: EE 3220

Project on Transformer
Design
Submitted To:
Md Habibullah Abu Syed Md. Jannatul Islam

Professor Professor

Department of EEE,KUET. Department of EEE,KUET.

Submitted By:
MD. MAHMUDULLAH RIYAD 1903061
MST. BRISTY KHATUN 1903062
SINTHIA ISLAM 1903063
MD. SADMAN SAKIB 1903064
FAISAL ISLAM 1903065
SHEMANTA MAJUMDER 1903066
JUHAYER MAHTAB TASIN 1903067
Objectives:

The main objectives behind designing of the transformer are given below:

 To be familiarized with the internal construction of a transformer.

 To learn about basic working principle of transformer.
 To learn about different theoretical considerations for different types of
transformers.
 To learn about the core, the windings and other important parts of the
transformer.
 v. To size the core by considering the nearest commercially available
lamination of external size of the core of the transformer.
 To be able to calculate the number of turns, the number of layers and the
amount of current in the windings.
 To be able to calculate the commercially available diameter of the wire used
for the windings.
 To demonstrate the transformer according to the values calculated.

Introduction:
It is a process by which primary coil induces a voltage into the secondary coil
with the help of magnetic induction. The coil windings are electrically isolated
and magnetically connected around a common circuit called core. If we apply
varying current in one coil, it results in creating a magnetic field and
automatically induces the varying voltage in the secondary coil. Hence power
is transmitted from one coil to another through the magnetic field. A slight
change in current in transformers helps in increasing and decreasing the AC
voltage in many electrical power applications. So, we can say that a
transformer carries the below operations:

(i)Transfer of electrical energy from circuit to another

(ii)Transfer of electrical power through electromagnetic induction

(iii)Electric power transfer without any change in frequency

(iv)Two circuits are linked with mutual induction

A transformer is a device that uses the principles of electromagnetism to

convert one voltage or current to another. It consists of a pair of insulated
wires wound around a magnetic core. The winding to which we connect the
voltage or current to be converted is called the primary winding and the
output winding is called the secondary winding.

Parts of transformer:

The main parts of a single-phase transformer are

1. Core

The core acts as a support to the winding in the transformer. It also provides a
low reluctance path to the flow of magnetic flux. The winding is wound on the
core as shown in the picture. It is made up of a laminated soft iron core in
order to reduce the losses in a transformer. The factors such as operating
voltage, current, power etc. decide core composition. The core diameter is
directly proportional to copper losses and inversely proportional to iron
losses.
2. Windings

Windings are the set of copper wires wound over the transformer core. Copper wires are
used due to:

*The high conductivity of copper minimizes the loss in a transformer because

when the conductivity increases, resistance to current flow decreases.

*The high ductility of copper is the property of metals that allows it to be

made into very thin wires. There are mainly two types of windings-
Primary windings and secondary windings.

Primary winding: The set of turns of windings to which supply current is fed.

Secondary winding: The set of turns of winding from which output is taken.
The primary and secondary windings are insulated from each other

using insulation coating agents.

3. Insulation Agents

Insulation is necessary for transformers to separate windings from each other

and to avoid short circuit. This facilitates mutual induction. Insulation agents
have an influence on the durability and the stability of a transformer.
The insulation that are used in a transformer are- Insulating oil, insulating
tape, Insulating paper, Wood based lamination etc.

Transformer classification

According to core design the transformers are classified into two types like core type and
shell type.
The major difference between these two transformers is the arrangement of
core and winding in the construction. In core type, the magnetic core includes
2-limbs & 2-yokes whereas, in shell type, it includes 3-limbs and 2-yokes.
There are certain types of transformer:

Power Transformers: Used in power distribution and transmission.

Distribution Transformers: Step-down voltage for local distribution.
Instrument Transformers: Used for measuring current and voltage in power
systems.

Design parameters

For designing a transformer, we require:

*Power rating

*Voltage levels (primary and secondary)

*Currents on both sides

*Iron core area

*Number of turns (primary and secondary)

* Primary and secondary coils wire diameter/size

*Efficiency
 Calculation

We projected to design a single-phase transformer of 80VA, with 220V/30V

voltage ratio. Efficiency is assumed approximately 90% and voltage drop in
the secondary is 10%.

Core Size:

Assuming utilization coefficient, Ku = 2.5X 10-2

We can determine the flux, which is the same for the three wound columns:

We can determine the flux, which is the same for the three wound columns:

Ø = Ku √kVA/f

= 2.5 X 10-2X √(0.08/50)

= 0.1 X 10-2 Wb

When an induction B = 1.1 Wb/m2 is fixed, it is possible to calculate the

area of the net iron section Air = Ø/B = 0.09 X 10-2 m2

The column width is approximately

C = (VA)1/4 = 3 cm

= 30 mm

Depth of core = Air / C

= 30 mm

Lpo =(30/0.9) =33.33

Lamination thickness is approximately 0.5 mm No

of lamination = 30 / 0.5 =67 laminations

32X32

15 mm
47 mm
 16 mm

96 mm 32 mm
mmm

16 mm

49 mm 16 mm

Wire size:

Voltage per turn, e = 4.44 f Ø

=4.44 X 50 X 0.1X 10-3 =0.22 V

The number of primary turns per phase

=220 / 0.22

= 990.99 =991

The number of secondary turns

= (30+30 X 0.1)/0.22=150

Efficiency is assumed, n = 90%

Primary current, I1 = 80/(0.9 X220) =0.40 A

Assuming current density 3.5 A/mm2

Acu = 0.12 mm2

 Hence, Primary conductor diameter = 0.380 mm

Commercially 0.38 mm is available whose SWG is 28.

Secondary current, I2 =(80/30)A =2.67 A

Acu = (2.67 / 3.5)

= 0.76 mm2

Hence, Secondary conductor diameter = 0.98 mm

Commercially 1 mm is available whose SWG is 19.

Using wire with enamel clad, total diameter is,

Ø1s = 0.380 mm

Ø2s = 0.98 mm

Useful height of reel = 47 mm

No of turn per layer, N1=(47/(1.05×0.38)) =118

N2 = 45

Sp= (991/118) = 9

Ss= (150/45) = 4

Radial dimension = (9×0.38)+(4×1)+(12×0.1)+(0.3×2)

= 9.22 mm

Discussion:
In this project, we initiated the design process by determining the volt-ampere (VA)
requirements to calculate the core size for a single-phase step-down transformer. The
calculated value led us to select a standard core size, utilizing E, I laminations. We opted for a
lamination thickness of 0.5 mm, resulting in 67 laminations.

Next, we determined the suitable wire sizes for the primary and secondary windings, arriving at
SWG 28 for the primary and SWG 19 for the secondary. Enamel-clad wire was chosen, and we
calculated the number of turns per layer on the reel for both windings. During the winding
process, we incorporated leatheroid insulation paper between layers to ensure proper
insulation.

Upon completion of the winding, we assembled the laminations onto the reel to construct the
core. Despite encountering some design errors, which had a negligible impact on the calculated
volt-ampere ratings, the transformer's turns ratio closely matched the theoretical values under
various conditions.

To validate the transformer's performance, we conducted load tests. The primary current
measured 0.40A, and the secondary current was 2.67A. SWG 28 and 19 proved sufficient to
withstand these currents. Additionally, the no-load current registered at 5%, well below the
acceptable threshold of 10%. This result was commendable.

In conclusion, despite minor design challenges, the overall execution of the transformer design
aligned with our desired model. The calculated turns ratio, load test results, and current values
demonstrated the successful design and implementation of the single-phase step-down
transformer.

References:
[1] A.K. Sawhney, A Course In Electrical Machine Design, 2nd ed.,

Dhanpat Rai & Sons, 1991

[2] Electronics Workshop, De Lorenzo, Kit For Transformer

Construction 2018

[3] China Silicon Steel Sheet, Transformer Core Manufacturer, Manufactory,

Factory and Supplier - Centersky Electrical Appliance Co., Ltd. (ecvv.com)

[4] AWG/SWG to mm/mm2, inch/inch2 & kcmil Calculator & Conversion

(electricaltechnology.org)