Course title: Electrical Machine Design

Course code: EE424

Section: A

Assignment # 01

Name: Huzaifa Tahir ID: F2017019044

Q1. (20 marks) Explain the following winding types: cylindrical winding, helical windings, double
helical windings, multi-layer helical windings, cross-over windings, disc and continuous disc
windings, and aluminum foil windings. (CLO1)

Cylindrical Windings
Cylindrical winding are layered type windings and uses a rectangular or round conductor. The
conductor is wound on flat sides and also on the rib sides. The layers are separated through oil
duct which is facilitated by the cooling process through oil circulation in the winding. The material
used for cylinder is solid paper Bakelite. This type of windings is that in which coil is helically
wound either as a single layer or multiple layers. The axial length of the coil used in it is usually
several time of its diameter. The maximum diameter for a bare conductor is 4mm.

Uses: -
• They are used up to 6.6 kV for kVA up to 600-750 and current rating between 10
to 600 A.
• If the winding is multilayered cylindrical winding, then this is used for high
voltage ratings up to 33kV,800 kVA and current rating up to 80 A.
 Helical Windings
Helical winding is used for low voltages and high current winding in large generator transformers.
Due to its distinct design, there is an effect on eddy current’s. The output of the transformer varies
from 160 – 1000 kVA from 0.23-15 kV. To secure adequate mechanical strength the cross-
sectional area of the strip not made less than 75-100 mm square. The maximum number of strips
used in parallel to make up a conductor is 16.

Uses: -

• Used in high-capacity transformers where current is higher but the winding turns
remain same

Double Helical Windings

It has same structure of helical winding but the number of parallel conductors in a radial direction
are reduced and because of it eddy current loss in conductors. There is only one layer of turns in
each winding. These windings are also referred to as screw or spiral windings, with each term
accurately characterizing the coil’s construction. The uses are same for as uses presented in helical
winding.
 Multi-Layer Helical Windings
This type of windings is used where high voltages are required which have a range of
110kV above. They are wounded on a paper cylinder and the layers are separated through
a vertical oil duct due to their arrangement. They improve the surge behavior. The layer
become shorter as the coil moves outside. As this winding is used for high voltage winding,
capacitance effect is prominent and needs to be given proper attention. This capacitance
controls the surge behavior of transformer. To improve the surge behavior of transformer,
capacitance should be distributed uniformly, which is done by making outer layers shorter.
However, it is to be noted that this reduces mechanical strength as well as leakage
reactance.
 Cross over Windings

When several coils are made circular cross-section and are placed in series,then
Distributed Cross-over windings are made..Each section of coils are seperated from
other section of coil by insulating material to provide insulation as well as duct for
cooling.Wires are covered with paper and at the inside end is connected to the outside
end with the help of an adjacent coil, The axial length of the coil is 50mm while the
width of coil ranges between 25-50mm and the spacing between the coils are 6mm.

Uses: -
• Cross-over windings are suitable for current not exceeding about 20A.
• Cross-over windings are mostly used in high voltage windings in samll
transformers in the distribution range

Disc and continuous disc windings

When four to five conductors of different sizes are connecting i n series and are placed
in the axial direction, then Continuous Disc Winding are made . ducts are placed
between each conductors to reduce eddy losses (heating losses) . Four to five conductors
are joined to form a single turn for high mechanical strength and to withstand of high
axial forces.

Uses: -
• Continuous Disc Winding are used for voltage between 33kv and 132kv
and medium current rating.
 Aluminum foil windings
The aluminium foil used for transformer winding is required high-quality pure aluminum as raw
materials which has high conductivity, soft characteristics, smooth surface, is an ideal material
for the production of dry-type transformers, and the key raw material for transformer winding.The
disadvantage of this foil winding is that it has poor mechanical strength with a poor workability.
It also increases the cross-sectional area of the coil used in windings.