AIR UNIVERSITY

PAF Complex, Sector E-9/4, ICT 46000

INSTITUTE OF AERONAUTICS AND AVIONICS

Department of Mechanical & Aerospace Engineering

Electrical Machines Lab

Semester Project Report
“Design of Transformer”
Submitted By:
Ahmad Sabur Hassan (160418)
Muhammad Ali (160900)
Muhammad Saad (160410)
Raja Areeb Sultan (160378)
Umar Saeed (160404)
BEME F-16(B)

Submitted To:
Sir Saud Alam
 Transformer
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 purpose of a transformer is to change electrical voltage to a different value. The
electrical component transformer that has the ability to change the level of voltage and current,
by means of two coils wound around a common core or center. The core consists of a large
number of sheets or sheets made of an alloy of Iron and Silicon. This alloy reduces losses by
magnetic hysteresis (ability to maintain a magnetic signal after a magnetic field has been
removed) and increases the resistivity of the Iron.

Need of Transformer:

In most of the cases, appliances are manufactured to work under some explicit voltage.
Transformer is used to adjust the voltages to a proper level. The transformer is the basic
components for the transmission of the electricity.
Transformer is used to increase the voltage at the power generating station (step up) and to
decrease the voltage (step down) for household persistence. By increasing the voltages, the loss
of the electricity in the transmission purpose in minimalize.

Working Principle of Transformer:

The main principle of operation of a transformer is mutual inductance between two circuits
which is linked by a common magnetic flux. 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.

Principle of Changing Voltage:

Before starting the construction of the transformer, one must know how the voltage and current
change across the transformer from primary to secondary winding as per required. The change in
voltage or current that a transformer makes happens thanks to the fact that the secondary winding
is induced by a magnetic field produced by the primary winding together with the core. The
change in voltage or current that the transformer delivers is inverse, that is, when the transformer
increases the voltage, the current drops; and when the voltage drops, the current goes up. This
brings us to a law: the energy delivered by a transformer cannot be greater than the energy that
enters it.
For the construction of transformer first of all we should have to know the necessary data and
calculations required for number of turns, primary windings and others as required.

Calculations for Transformer Design

There is a relationship between the turns of the primary winding and the secondary winding. This
ratio determines the output voltage of the transformer and they are the same, the ratio between
the turns of the windings and the input and output voltages.
When the primary winding is equal to the secondary winding (1: 1), the input voltage and current
are equal to the output voltage and current. In this case this transformer only serves to make a
galvanic isolation, that is, we can touch the output current without being electrocuted.
By changing the turns of the secondary winding wire, the transformer output voltage changes.
Example: if for each turn of the primary winding, we make three turns in the secondary; we
would have, in the case of applying a tension of 10 volts at the input, at the output would be 30
volts. Y When we wrap one turn of wire in the secondary for every three turns of the primary; in
the case of applying a voltage to the input of 30 volts, we would have 10 volts at the output.

Design Parameters:
For designing a transformer, we need:

 Power rating
 Voltage levels (primary and secondary)
 Currents on both sides
 Primary and secondary coils wire diameter/size
 Iron Core area
 Numbers of turns (primary and secondary)
Specifications:

Area of Transformer Core:

Now the core section is related to the total power as follows:
Core Area = √S

Area=A= √55 ≈ 7.42 cm2

So, we use the square sheet of cross section 2.75cm x 2.73cm
By using these dimensions, the area of the core become approximately equal to the area we find.
Area=A=¿2.75cm x 2.73cm = 7.5cm2

Number of turns of the copper wire:

To calculate the number of turns or turns of copper wire divide 42 by the area of core.
Number of turns per unit volt = 42/Area of core
= 42/7.5
= 5.6 turns of wire per volt

Primary Winding Calculations:

For Transformer Design Calculation we first calculate parameters for Primary side then
secondary side.
V p=220V

Apparent Power=S=55 VA
 VA 55
I p= = =0.25 A
V p 220

Primary side number of turns can be calculated as:

Total number of turns ( N 1) = turns per volts x primary side voltage
N1 = 5.6 x 220 = 1232 turns

Size of Primary Conductor:

As the current density is given by current per unit area i.e.
I
δ=
A
As, for copper the current density is taken as 2.3 A /mm2 . So, for area of copper conductor of
primary side (a1)
I 0.25
a 1= = =0.1087 mm2
δ 2.3
So, from standard AWG table we can find out size of this area which is 27 AWG. From the
standard American wire gauge table, we can choose wire of the same thickness. It can be seen
that it comes out that required primary side wire is of 27 gauge which can conduct required
current.
AWG wire gauge = 27
SWG wire gauge = 28

Secondary Winding-I Calculations:

V s =380 V

VA 55
I s= = =0.15 A
V s 380

Total number of turns ( N 2) = turns per volts x secondary side voltage

N 2 = 5.6 x 380 = 2128 turns

Size of Secondary Wire:

I 0.15
a 2= = =0.0652 mm2
δ 2.3
From the standard copper wire, table it can be seen that wire of this thickness is of 29 gauge. So,
Transformer Design Calculation for secondary winding we need 29-gauge wire.
Hence, Secondary Wire = 29 AWG
AWG wire gauge = 29
SWG wire gauge = 32

Secondary Winding-II Calculations:

V s =220 V

VA 55
I s= = =0.25 A
V s 220

Total number of turns ( N 2) = turns per volts x secondary side voltage

N2 = 5.6 x 220 = 1232 turns
Size of Secondary Wire:
I 0.25
a 1= = =0.1087 mm2
δ 2.3
From the standard copper wire, table it can be seen that wire of this thickness is of 27 gauge. So,
Transformer Design Calculation for secondary winding we need 27-gauge wire.
Hence, Secondary Wire = 27 AWG
AWG wire gauge = 27
SWG wire gauge = 28

Calculation Results:
Specifications Primary Winding Secondary Secondary
Winding-I Winding-II
Rated Voltage 220 V 380 V 220V

Rated Current 0.25 A 0.15 A 0.25 A

No. of Turns 1232 2128 1232

Wire Gauge (AWG) 27 29 27

Wire Gauge (SWG) 28 32 28