Proceedings of IOE Graduate Conference, 2019-Winter

Peer Reviewed
Year: 2019 Month: December Volume: 7
ISSN: 2350-8914 (Online), 2350-8906 (Print)

Transformer Design using MATLAB

Praveen Giri a , Sudip Babu Dhakal b , Shishir Acharya c ,
Shailes Sigdel d , Shahabuddin khan e , Menaka Karki f
a, b, c, d, e, f
Department of Electrical Engineering, Pashchimanchal Campus,
Institute of Engineering, Tribhuvan University, Nepal
Corresponding Email: a [email protected] , b [email protected], c [email protected],
d [email protected], e [email protected], e [email protected]

Abstract
Transformer is based on the principal of mutual induction from primary winding to secondary winding due to
alternating current. The design calculation of transformer is a hectic process when done manually. Since
the calculation is long and interdependent with each steps the occurrence of error is more likely so use
of computation system can minimize the error. For this use of MATLAB to have a software to design the
transformer providing the design parameter is the main objective of the paper. With the Graphical user interface
(GUI) and app designer helps to simplify the process and make it more user friendly which provide space for
input values and options to choose. The software make calculation regarding the dimension, efficiency and
manufacturing cost of the specified transformer. In addition, the software would be useful for the education
and research purpose.
Keywords
App, Efficiency, GUI, MATLAB, Transformer

1. Introduction Faraday’s law of electromagnetic induction [1].

Transformer is a crucial component of any electrical Faraday’s law states that “Rate of change of flux
system as it allows to work on different voltages level. linkage with respect to time is directly proportional to
It is a static device where transfer of energy takes place the induced EMF in a conductor or coil”.
through the magnetic coupling. When the alternating The basic transformer consists of two types of coils:
current is passed through the primary winding then
Primary coil: The coil to which the supply is given is
varying magnetic field is produced whose amplitude
called the primary coil.
will depend on the primary voltage, the frequency of
the applied voltage, and the number of turns. Secondary coil: The coil from which the supply is
taken is called the secondary coil.
Based on the required output voltage the number of
turns in the primary coil and the secondary coil are
varied. The processes occurring inside the transformer
can be grouped into two:
Figure 1: Basic Construction Detail of Transformer
Magnetic flux is produced in a coil whenever there is
a change in current flowing through the coil.
A transformer is based on the principle that energy Similarly, change in magnetic flux linked with the coil
can be efficiently transferred by magnetic induction induces EMF in the coil. The first process occurs in
from one winding to another winding by a varying the windings of the transformer. When the ac supply
magnetic field produced by alternating current. The is given to the primary winding alternating flux is
magnetic circuit or core of a transformer is designed produced in the coil. The second process occurs in the
to provide a path for the magnetic field, which is secondary winding of the transformer. The flux
necessary for induction of voltages between the alternating flux produced in the transformer links the
windings. Transformers work on the principle of

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Transformer Design using MATLAB

coils in the secondary winding and hence emf is 2.2 Windings of transformer
induced in the secondary winding.
Core type use concentric type of winding i.e.
Whenever an ac supply is given to the primary coil, cylindrical, helical, cross-over or disc. In this paper
flux is produced in the coil. These flux links with for H.V. and L.V., the area of conductors in primary
the secondary winding thereby inducing emf in the and the secondary windings is determined after
secondary coil. This is the very basic working of the choosing a suitable current density to be used in the
transformer. windings.
Temperature rise in the windings may become
The voltage produced in the secondary coil depends
excessive if higher values of current density are
mainly on the turn’s ratio of the transformer. The
chosen and this may cause injury to the insulation.
relationship between the number of turns and the
Hence the choice of current density is important in
voltage is given by the following equations [2].
this paper as the I 2 × R losses and the load at which
the maximum efficiency occurs depends on it. For
N1 /N2 = V1 /V2 = I2 /I1 (1) minimum I 2 × R losses, the value of current density in
each of the two windings should be equal. Primary
Where, current and secondary current are respectively as:
N1 = number of turns in the primary coil of the
transformer.
N2 = number of turns in the secondary coil of the Q × 10−3
I1 = (2)
transformer. 3V1
V1 = voltage in the primary coil of the transformer.
V2 = voltage in the secondary coil of the transformer. Q × 10−3 N1
I2 = OR I1 (3)
I1 = current through the primary coil of the 3V2 N2
transformer. Sectional area of primary winding and the secondary
I2 = current through the secondary coil of the winding are respectively as:
transformer. I1
a1 = (4)
δ

I2
2. System Framework a2 = (5)
δ
The paper shows the how automated calculation work Where δ is current the density.
can be done in MATLAB with the help of app design. Now we can use round conductors or strip conductors.
The app developed for design of transformer is shown For this, the IS codes and ICC (Indian Cable
in figure 2. The program is coded to perform the Company) table can be referred.
task. The user enters the data as per their requirement Number of primary turns for %tapping = T2 × E1
using specified standard design data and then design requiredE2 with tapping.
parameters are calculated automatically. The required
data and standard data are shown in figure 3.

2.3 Specification of Core and frame

2.1 Data input and parameter calculation
Core type transformer generally uses rectangular or
The parameter that are determined are: stepped core. Also core type distribution and small
and medium power transformer uses rectangular core.
The ratio of depth to width of the core varies between
a. Winding Design
1.4 to 2. Square core is used when circular coils are
b. Window Design
required for high voltage distribution transformer. On
c. Resistance and reactance
circular coils forces by excessive leakage flux due to
d. Tank Design
short circuit are radial and there is no tendency for the
e. Efficiency
coils to change its shape. As the size of transformer
increases it become wasteful to use rectangular coils

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 Proceedings of IOE Graduate Conference, 2019-Winter

Figure 2: MATLAB GUI APP

following relation [1].

f luxmax
Ai = (7)
Bm
Where f luxmax is the maximum flux which is given by
following relation.
Et
f luxmax = (8)
4.44 × f
The gross core area (Agi ) is given by following
relation.

Ai
Agi = (9)
k
Where, ki is the stacking factor
Kw is the window space factor, it is the ratio of the
copper area in the window of the total window area,
it depends upon the relative amount of the insulation
Figure 3: Input Data for the Model and copper provided which in turn depends upon the
voltage rating and output of transformer.

hence in this paper, we used stepped core.

8
Kw = (10)
p 30 + KV
Et = k × Q (6) Diameter of circumscribing circle,
r
Where, Ai
D= (11)
Et is the voltage per turn .56
Q is the rating of transformer
Ai is the net core area required which is obtained by

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Transformer Design using MATLAB

The net core area required is obtained as: The copper loss depends on the loading and thus is a
Ai = 0.56 × D2 (12) variable loss. It is calculate as:

Finally, the output of the transformer is given by the

following relation: Total I2 × R loss = [3 × I2 × R + stray loss] (21)
Q = 3.33 × f × Bm × δ × Aw × Ai (13) Where, stray losses is taken around 15% ofI2 ×Rlosses.
However, core loss is constant loss that is independent
Where, Aw is the area of the window defined as:
on the loading and is given as:
Aw = Hw ×Ww (14)
Total Core loss = [losses in limb + losses in yoke]
Hw and Ww is the height and width of window (22)
respectively. The distance between adjacent core
centers is defined and given as [1]: Now, the efficiency of the transformer could be
calculated as the ratio of actual output power to the
actual input power calculated as:
output
d = Ww + D Efficiency = (23)
output + loss
Ay = (1.25 to 1.5) ∗ Agi (15)
The
qloading at which the maximum efficiency occurs
is PPci percent of full load. No load current Io consists
Where, Ay is the area of yoke. Area of the yoke is 15
of two components, magnetizing component Im and
to 25% larger than that of the core for hot rolled steel
wattage component Il ,
transformer, but of the same area as core in cold rolled s
grain oriented steel transformer. Im2
I0 = (24)
I12

W = 2×d +a (16) Total magnetizing mm f is given as:

Tmm f = 2 × ATC × lc + 2 × aty × ly (25)
Where, d is the distance between adjacent core centers.
Height of yoke is given as: where,
Ay aty is magnetizing mm f in the yoke.
Hy = (17)
Dy
H is the height of the frame and Hy is the height of the
yoke. 2.5 Specification of Tank
Tank bodies of the transformers are made up from
rolled steel plates which are fabricated to form the
H = Hw + 2 × Hy , (18)
container. Small tanks are welded from steel plates
The width of the frame is given as: while larger ones are assembled from boiler plates.
W = (2 × d) + s (19) Tanks are provided with lifting lugs, small
transformers have cooling tubes let into the vertical
Where, s is the width of laminations. sides, but large transformers require separate banks of
cooling tubes. Such transformers have plain tanks
2.4 Losses and Efficiency with provision for pipes and valves to direct and
The total losses decrease if the frequency increased control the oil flow. Stray load losses and cost should
and the applied voltage is kept constant, hence with be considered. The tank should be strong enough to
increased frequency we can afford to have more I2 × withstand stresses produced by jacking and lifting.
R loss and thus for the same loss the rating of the The size of the tank is taken large enough to
transformer can be increased. accommodate cores, winding’s, internal connections
The total loss in the transformer constitute core loss and also must the requisite clearance between the
and the copper loss given by: winding’s and the walls. The temperature rises as
calculated with plain tanks exceeds the specified limit,
but it brought down by the provision of tubes, it
Total losses = Core loss + I2 × R loss (20) increases the dissipation area.

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 Proceedings of IOE Graduate Conference, 2019-Winter

Height of the tank is calculated as [3]: Table 1: Transformer Design Input Panel
= (H + h)/1000 (26) Transformer Capacity 25 kVA
Where, h is clearance between assembled transformer Primary Winding Voltage 11 kV
and the tank, Secondary Winding Voltage 400 V
H is height of the frame Current Density 22 A/mm2
Maximum Magnetic
150
Flux Density
Width of the Tank (in meters) is calculated as:
Ratio of Window
Wt = (2 ∗ D + dout + 2 ∗ l)/1000 (27) 2.5
height to window width
Where, dout is outside diameter of High Voltage Selection of maximum
450C
winding allowable temperature
Insulation Width 0.5 mm
Length of the Tank is calculated as: Tapping(±) 5%
Lt = (dout + 2 ∗ l)/1000 (28) pf 0.8
Three phase
Where, l is clearance on each side between winding Type
core type (oil)
and tank along the width. Clearance along the length
Winding Type Star-Delta
of the transformer i.e. l is greater than that along the
width of the transformer this is because additional Frequency 50 Hz
space is needed along the length to accommodate Core material Cold Rolled Steel
tapping. Z is the clearance between high voltage Core type Cruciform
winding and tank. Design Preference Normal
Transformer oil type Naphtha based
Total loss dissipating surface of the tank Output Constant (k) 0.45
St = 2 ∗ (Wt + Lt ) × Ht (29)
Table 2: Tank Design Output Panel
Temperature rise within tubes is given as:
θ = T L f l /(St × SL ) (30) Height of tank 850 mm
Width of tank 350 mm
If the value of the θ is below 35◦ C then plain tank is Length of tank 800 mm
sufficient for cooling and no extra tubes are required Temperature rise 26.18 ◦ C
for cooling of the transformer. Wall area of each tube 1.649×105 mm2
Number of tubes 0
Cooling type
3. Results and Discussion
The software works well without any error when
power.
checked using the standard data and calculation. The
calculation sample for one set of data has been Similarly, use of Three Phase transformers seems to
examined and presented here. However, the output be more practical economically and in terms of power
has been very well verified for different transformer efficiency then that of using Single phase transformer.
types and categories. For the same power supply, three phase transformers
are around 2% more efficient then single phase
These apps are supposed to meet the basic standard of
transformer, which is much significant [4].
NEA, for maintaining the maximum efficiency of at
least 97.5 % on the transformer. Designing of Power Transformer is made to operate
in maximum efficiency near full load and Distribution
We have found from several entry of input of
transformer is made to operate in maximum efficiency
transformer varying size and voltage level. And from
near its half load.
the output we can conclude that use of transformer
with high power rating and high level of voltage in Use of Cold rolled steel is more preferable in core
both primary and secondary winding would be more material than Hot rolled steel. Being produced in mass
economical and power efficient than that of number of production we find there is not so much price margin.
small transformers in parallel sharing equal amount of Therefore, use of Cold rolled Steel has more advantage

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Transformer Design using MATLAB

Table 3: Winding Design Output Panel Table 5: Resistance and Reactance Output
Primary Winding type Delta Resistance 257.1 Ω
Secondary Winding Resistance in p.u 0.01771
Star
type Reactance 2695 Ω
High Voltage Low Voltage Reactance in p.u 0.1856
Specifications Specifications Impedance in p.u 0.1865
Winding Primary Winding Secondary Regulation 0.1255
Number Number Insulation type F
4889 turns 103
of turns of turns
Number
With the program generates is the cost that in occur during
5133 of parallel 1
tapping
conductor
the manufacturing process.
Low
Number of
20 voltage 36.08 A With these output the user can also have the design
layer
current parameter data in report generation section. The report
High is available in .pdf or doc. format so that the user can
Current
Voltage 0.7576 2.062 print for the desired use.
Density
current A/mm2
Current Area of
0 A/mm2 17.5 mm2
Density conductor
4. Conclusion
Thickness
Area of
0.5027 of 2.5 mm To analyze the transformer parameter coding is done in
conductor
mm2 conductor MATLAB software. Application was developed with
Axial Width of the friendly GUI to take the input which is processed
32.5 mm 7 mm
height conductor by the program coded giving the design parameters and
Number Axial efficiency as the output. This system can be used for
8 88.33 mm
of coils height preliminary design of transformer for manufacturing.
Radial Radial
25.2 23.5 mm The software couldn’t be used for the manufacturing
Width width
process as the specification and parameters are within
Outside Outside
240 mm 159.8 mm limited range up to 500 kVA. The program can be
diameter diameter
improvised to accommodate the need and the demand
Inside Inside
189.6 mm 112.8 mm also. The mere purpose of the project is to make it as
diameter diameter
an educational tool.
Table 4: Loss and Efficiency Output Panel

Losses(Watt) Efficiency
References
Full load
Copper loss 442.7 97.5 %
efficiency [1] AK Sawhney and A Chakrabarti. Course in electrical
Stray loss with Half load machine design. Dhanpat Rai, 2010.
509.1 97.98 %
Cu loss efficiency [2] MultiMedia LLC. A brief history of transformer.
Maximum [Online] https://acupwr.com/blogs/news/
50.66 % of 80121091-a-brief-history-of-transformers,
Loss across limb 46.22 efficiency
full load 2016.
occurs at
Loss across yoke 84.43 [3] Nileema Patil and JH Patil. Design and analysis of
Total core loss 130.6 transformer using matlab. International Journal of
Science Technology and Engineering, 1, 2015.
Total loss 639.8
[4] Transformer. [Online] http://www.
newworldencyclopedia.org/entry/
on designing of transformer. Similarly, the output that Transformer, 2015.

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