CAD-based Design of Three Phase Transformer and

Comprehensive Analysis for Wind Turbine Using

Coupled Electromagnetic Field, Circuit and Thermal
Model for 3.8 MVA Power
Yucel Cetinceviz  (  ycetinceviz@kastamonu.edu.tr )
Kastamonu University
Erdal Sehirli 
Kastamonu University

Research Article

Keywords: transformer design, co-simulation, inductance matrix, inrush current, core loss, multi-physics
analysis

Posted Date: October 18th, 2022

DOI: https://doi.org/10.21203/rs.3.rs-2158292/v1

License:   This work is licensed under a Creative Commons Attribution 4.0 International License.  
Read Full License
 CAD-based Design of Three Phase Transformer and Comprehensive Analysis for Wind Turbine Using Coupled
Electromagnetic Field, Circuit and Thermal Model for 3.8 MVA Power
Yucel Cetinceviz* and Erdal Sehirli
Abstract
In this study, by using co-simulation technique, dry type
transformer is designed for wind turbine with 3.8MVA,
690V/36kV power and voltages. Transformer used in wind
turbine needs extra effort on design stage with respect to the
transformer used in transmission and distribution systems due
to higher inrush currents, resonance overvoltage, higher
voltage and load fluctuations, possible high frequency
transients causing the damage of insulation of the transformer.
Also, variable output because of the variable wind speed is
expressed as a common failure of the transformer stated in,
although by power converters the problem can be minimized.
Furthermore, transformer design and analysis of its effect to
the system, cannot be realized through one simulation
software. Therefore, another approach using different
simulation software at the same time called as co-simulation
or multiphysics solution is needed. In this paper, by using, co-
simulation technique including ANSYS Maxwell 3D,
Simplorer and Mechanical, transformer design and its effect to
the system is investigated. After realizing, three-dimensional
transformer design, its lumped parameter consisting of
inductance matrix, leakage inductances and resistances are
determined analytically and by using eddy current solver.
Also, its effect on the system is shown by Simplorer in
transients. Core losses of the transformer, high and low voltage
windings voltages, their harmonic spectrums, under different
load conditions including ohmic and inductive loads defined
and also, steady state thermal solution performed and
conclusions are made. It is proved that the transformer
designed works as it desired.
Keywords: transformer design; co-simulation; inductance
matrix; inrush current; core loss; multi-physics analysis
* Corresponding author
Y. Cetinceviz
Electrical and Electronics Engineering, Kastamonu
University, Kastamonu, Turkey
Tel.: +90-555-644-5997;
E-mail address: ycetinceviz@kastamonu.edu.tr,
Orcid: 0000-0001-6834-9442
E. Sehirli
Electrical and Electronics Engineering, Kastamonu
University, Kastamonu, Turkey
E-mail address: esehirli@kastamonu.edu.tr,
1. Introduction
Due to the negative effects of carbon-based energy sources
to the nature, usage of renewable energy has gained much
attention for last a few decades. One of the most important
renewable energy sources is the wind power. Wind power can
be transformed to the electrical energy by using wind turbine,
1
generator, transformers and gearbox mainly. After obtaining
electrical energy by wind generator, to transfer this energy a
power transformer with high efficiency and minimal energy
losses [1] should be used in the level of distribution system [2]
because it is not possible to store wind energy. So, this
transformer used in wind energy generally has a step-up
characteristic. Besides, the transformer can be dry type or oil
cooled type [3, 4]. With respect to the oil cooled transformer,
dry type transformer has the advantages of non-flammability
and lighter. So, it provides higher safety for distribution of
electrical system. In addition, being lighter feature of dry type
transformer make the transformer to locate in the windmill
nacelle possible [5-6]. Also, the design procedure is more
different than designing traditional distribution transformer,
hence transformer primary voltage changes with wind speed
that has random characteristic. Also, Because of the random
characteristic, the voltages may have harmonic content. So,
transformer for wind turbine should overcome these two main
problems, lower harmonic content and reliable power supply
with respect to change in the wind speed and variable output
conditions.
In addition, wind energy is transformed from wind power
into electrical energy for grid through some components that
are wind turbine, gearbox, generator, power converter,
transformer.
In literature, design issue of transformer has found lots of
interest, in [7] a review is made on wind turbine transformers.
[8] designs a wind turbine using 3D wound core. Protection
methods of wind turbine transformers against high frequency
transient is investigated [5]. [9, 10] analyses wind turbine
transformers on resonant over voltage effects. An improved
design taking into account the resonance problem because of
the high frequency transient for wind turbine transformer is
realized in [11]. [12] compares the wind turbine and
distribution transformers with respect to dissolved gas
occurred due to the operation of transformer. Probabilistic
analysis of switching transients of wind turbine transformers
because of the operation of breaker is included in [13]. In [14],
failure analysis of wind turbine transformers regarding on over
temperature is made. A 3-phase transformer model is
established in the MATLAB Simulink environment to
introduces a time domain model of a 3-phase, 2-winding
transformer with nonlinear and hysteretic behavior in [2].
Detailed three phase transformer and inductance design are
presented as in [15]. In [16], power transformer windings
deformation analysis in short circuit fault is analysed by using
finite element method (FEM), also in [17-19] by using FEM,
power transformer transient analysis is realized. Power
transformer is also modelled by using FEM as in [20, 21].
Transformer design for wind turbine considering internal
resonance is carried out in [22]. In [23] for wind power
application, a three-phase rotary transformer is designed and
analyzed. Co-simulation technique is used and proved to the
convenience of application for autotransformer in [24]. Also,
studies at different power and voltage range are given in Table symmetry multiplier 2 (symmetry factor). Besides, it is
1. important to start with a suitable mesh operation to reduce
computation time and provide accurate analysis [24]. A length
Table 1. Wind turbine transformers in literature. based mesh is created throughout the volume of core and
Power Low/High voltage Reference windings. And also maximum number of elements are set to
10000 for core and windings.
800kVA 0.69/20kV [8]
1.6MVA 0.4/33kV [25]
3.14MVA 0.4/35kV [26]
2.7MVA 0.69/33kV [27]
6.7MVA 0.66/33kV [28]
800kVA 0.69/20kV [10]
1.5MVA 0.69/33kV [29]
4MVA 0.69/34kV [30]

It is still a common problem to design a transformer and to

provide its operation in at the same time in one simulation even
for distribution systems. The design and operation of the wind
turbine transformer needs extra care because of the randomly a) b) c)
change nature of the wind speed resulting different transformer Fig.1 3-D model of the designed wind turbine transformer,
voltages and variable outputs, also over voltages due to the (a) 3D symmetry model; (b) 3D full model; (c) mesh
high frequency transients. Besides, thermal analysis is crucial operation.
and must be taken into account in the correct design of
electrical machines. Values of specific magnetic loading and While designing the transformer, main electrical
specific electric loading and/or current density for a certain parameters such as power, voltage and frequency should be
electrical machine should be limited to prevent overheating. defined, also material of the transformer core, type of
conductor should be chosen. In Table 2, parameters that are
In this paper, three phase dry type, step up wind turbine required to design transformer is given.
transformer design is realized and the effect of the designed
transformer to the system is investigated by using co- Table 2. Electrical and material properties of the design.
simulation technique including ANSYS Maxwell and Parameter Values
Simplorer software. Furthermore, core loses of the
transformer, high and low voltage windings harmonic Power 3.8 MVA
spectrums is presented. Also, operation of the transformer Voltage 0.69/36 kV
under different load conditions including ohmic and inductive Frequency 50 Hz
loads is analysed. The multiphysics simulation consisting of Mass density 7650 kg/m3
three-dimensional coupled electromagnetic field-circuit
(cosimulation) and thermal analysis approach which are used Frequency 50 Hz
in order to justifying the analytical and three-dimensional Core material Thickness 0.35 mm
FEM model of power transformer is one of the most M270-35A Conductivity 1923000 S/m
remarkable contribution of this study. Unlike previous (M19) Kh 134.001 W/m3
reported studies, the most important contribution of this study
Kc 0.387493 W/m3
is that it offers an effective model that includes no-load, full-
load, short-circuit, in-rush current analysis and inductance Ke 1.17493 W/m3
matrix, leakage inductance, resistances calculation and Winding material Copper
thermal analysis. Phase number 3
2. Three phase transformer design for wind In Figure 1, 3D model of the transformer is given. Also, in
turbine Figure 2, 2D model of the transformer is shown and, on that
Before designing the transformer, it is good to visualize the figure, transformer core, phase windings and dimension
structure of transformer. In Figure 1, 3D model of the three- descriptions of the core are given. As it is seen that three phase
phase transformer and its windings are shown including windings of transformer are wounded as shell type. HV and
symmetric model, full model and mesh operation. This 3D LV are meaning as high voltage and low voltage, respectively.
model is realized by using ANSYS Maxwell 3D software. It is
always a good idea to apply symmetry boundary condition in
order to reduce computation time since the model needs to be
refined for accurate analysis. This symmetry definition is
equivalent to full model with applying the correct symmetry
boundary condition as shown in Figure 1. Then all parameters
will be rescaled to take into account the full model by setting

2
 One of the most important characteristics to design a
magnetic material is the B-H curve due to defining the
saturation of the transformer. The B-H curve of the M270-35A
material is given in Fig. 3a. It is seen that close to 2T, the core
has saturation. Therefore, in the design 1.5T is chosen as the
maximum flux density.

Fig. 2 Transformer core, windings and dimension

descriptions.
Transformer power can be written with respect to induced
winding voltage, (𝜑m) maximum flux in (Wb), number of turns
and frequency as in (1). Also, induced voltage per turn Et can
be summarized in (2). In (2), r is a constant that is a ratio of a)
𝜑m to AT, shown in (3). Also, AT means ampere turn given in
(3). Besides, f is frequency, N2 is number of turns of high
voltage windings, ph is phase and Is is phase current in (1-3)
as in [15]. Also, K is a constant that typically changes between
0.6 and 0.7 for three phase transformers.
S = 3  U HV  I S  EHV  I S
(1)
= 3  4.44  f  m  N 2  I s

U HV S S b)
Et = = 4.44  f  r  ( )= K (2)
N2 ph ph Figure 3. Magnetic properties of the M270-35A material, (a)
B-H curve; (b) core loss-magnetic flux density curve.
m
r= ; AT = N 2  I s (3) The other important characteristic of the core is the
AT
between core loss and flux density that is given in Fig 3b for
M270-35A core. It is seen by the figure that core loss changes
In transformer, dimension of transformer is proportional to
with magnetic flux density so while designing transformer, a
the transformer power level. In (4), cross section area (Ai)
convenient flux density should be chosen to reduce core loss
equation of the core is given and it consist of, induced voltage,
and not to provide saturation. Also, in Fig 3b, constant
frequency and maximum flux density (Bm) in Tesla. In (4),
parameters, Kh, Kc and Ke used in the design calculation are
equation of (d) core diameter is given and kc in that equation
given.
refers to stepped core coefficient. Width of yoke (DY) is given
in (5) and ki is stacking factor. Also, height of yoke (HY) can By using (1-8), calculated dimensions’ values of the
be calculated by using (5). In 6, equation of window area (AW) transformer for the desired is calculated and given in Table 3.
is given, KW is the window space factor and J is current density. with the description as in Figure 2.
In (7-8), window width (W), frame width (W) and frame height
(H) can be calculated. Besides, the ratio of (HW/WW) changes Table 3. Calculated dimension of the transformer.
between 2 to 4 in three phase power transformers. Required Dimensions
Et Ai Width of yoke (DY) 270mm
Ai = ; d= (4)
4.44  f  Bm kc Height of yoke (HY) 255mm
Distance between core 750mm
center (D)
Width of window 480mm
Ai
Hy = ; D y = ki  d (5) (W ) of window
Height 961mm
Dy
(H )
Width of frame (W) 1770mm
Et Height of frame 1486mm
Aw = (6) Cross section area (Ai) 0.057 m2
3.33  f  Bm  K w  J 106  Ai
In the design of windings for three phase transformers, the
A connection type of the windings is important. In this study, LV
W = 2Ww + 3Dy ; Ww = w (7) windings are connected as ∆ and the nominal voltage is chosen
Hw
as 690V. On the other hand, HV windings are connected as Y
and nominal voltage is chosen as 36kV.
H = H w + 2H y (8)

3
 For LV windings, (9-10) are used to calculate, number of
turns and diameter of conductor, N1, Ip, ap, j, dp refer to LV
winding number of turns, LV winding phase current rms value,
cross section of conductor, current density and diameter of
conductor, respectively.

U LV _ ph
N1 = (9)
Et

ap Ip S
dp = 2 ; ap = ; Ip = (10) a) b)
 J 3 U LV _ ph
Figure 4. Three phase transformer studied, (a) structure of the
For HV windings, (11-12) are used to calculate, number of two winding three limb core type; (b) equivalent magnetic
turns and diameter of conductor. Also, N2, Is, as, J, ds refer to circuit of the transformer for inductance calculations and
HV winding number of turns, HV winding phase current rms length of magnetic path of phases [33, 34].
value, cross section of conductor, current density and diameter Using the superposition theorem to equivalent magnetic
of conductor, respectively. circuit [35] of the transformer at no load, instantaneous values
of fluxes (ɸa, ɸb and ɸc) in every limb can be figured out by
U HV _ ph Eqs. (13–15), respectively [34].
N 2 = N1  (11)
U LV _ ph
N LV  ia (t ) Rc N  i (t )
a = −  LV b
R  Rc Ra + Rc R  Rc
as Is S Ra + b Rb + a
ds = 2  ; as = ; Is = (12) Rb + Rc Ra + Rc
 J 3  U HV _ ph (13)
Rb N  i (t )
−  LV c
Ra + Rb R  Rb
After design of three phase transformer, calculated Rb + a
parameters regarding to HV and LV windings are given in Ra + Rb
Table 4.
Rc N  i (t ) N  i (t )
Table 4. Calculated parameters. b = −  LV a + LV b
Rb + Rc Rb  Rc R  Rc
Ra + Rb + a
Design Parameters LV HV Rb + Rc Ra + Rc
Number of turns 40 1260 (14)
Rb N  i (t )
Turns ratio 0,03 −  LV c
Ra + Rb R  Rb
Rc + a
Cross section area of conductor 615mm2 23.32mm2 Ra + Rb
Conductor diameter winding 28mm 5.5mm
Outer diameter of winding 394mm 494mm Rb N  i (t ) Ra
c = −  LV a −
Mean length of winding 1.06m 1.41m Rb + Rc R  Rc Ra + Rc
Ra + b
Winding resistance 0.705mΩ 1.14Ω Rb + Rc
(15)
Winding connection Delta (∆) Star (Y) N  i (t ) N LV  ic (t )
 LV b +
R  Rc R  Rb
Rb + a Rc + a
2.1. Inductance calculation for designed transformer Ra + Rc Ra + Rb
Precise calculation of inductance value is of great
importance in transformer design [31]. Fig 4a and 4b shows The reluctance Rb represents the leg of core, Ra and Rc
three phase three limb core type and magnetic circuit of three represent the sum of yoke and leg of core. In this asymmetric
phase transformers respectively. Analysis of the magnetic field configuration, the reluctances of A phase and C phase is
in the transformer is performed by applying the excitation thought to be same (Ra=Rc=R), magnetic path lengths are
current. Symmetrical excitation currents are applied for the ℓa=ℓc=l, also it is assumed that cross sectional areas are
magneto motive forces (FLV_a = NLV ia, FLV_b = NLV ib and Aa=Ab=Ac=A and all phases have same turns NLV_a = NLV_b =
FLV_c = NLV ic) required to produce instantaneous values of NLV_c = NLV. Besides, reluctances can be computed as follows;
fluxes (ɸa, ɸb and ɸc). The reluctance of a core section or air l lb
region as a limb of the magnetic circuit is obtained by magnetic Ra = Rc = , Rc = (16)
 A  A
energy and magnetic flux related to magnetic sections of the
core [32]. It is clear from the Fig 4b that there is a natural
asymmetry in the core as the length of magnetic path of phase Here µ=B/H is magnetic permeability [H/m]. Since the
B between the points P1 and P2 is less than that of phase A and flux linkages are λ1 =NLV ɸa, λ2 =NLV ɸb, λ3 =NLV ɸc and this
C. transformer configuration as shown Fig 4b marks that phase

4
winding 1 is coupled to all windings (1 to 6) the following 2
N LV  0  A a D a D
matrix form can be written; L =    ( 1 1 2 2 + g  Dg ) (24)
h 3
1 (t )   L11 L16  i1 (t ) 
      Where, h is height of windings, a1, a2 and ag are the radial
 =    (17)
lengths and D1, D2 and Dg are the mean diameters of LV, HV
 L66  i6 (t ) 
 6 (t )   L61 and gap respectively.

The self and mutual inductance terms (Lii and Lij) of the L
2.2. Eddy current analysis to extract lumped
matrix are obtained from excitation currents at nominal
parameters for designed transformer
frequency while LV three phase winding is excited and the
other HV three phase winding is open. Subscripts 1-3 and 4-6 Figure 5 shows one phase lumped model of transformer.
indicate LV and HV winding respectively. Self-inductances FEM is the most widely used numerical method for lumped
(Lii) [36] of three phase transformer can be found from the first parameter calculation [18] of structure and asymmetric flux
term of Eqs. (13–15) and mutual inductances (Lij) can be found distributions that cannot be accurately evaluated by analytical
from the other six terms of Eqs. (13–15) as follows; method [20]. The main advantage of the 3D FEM is that any
2 2 2
complex geometry can be solved, because the formulas run on
N LV N LV N HV finite elements depend solely on the problem class and are
L11 = , L22 = , L66 = ,
R  Rc R  Rc R  Rb independent of its geometry. In this study, Eddy Current solver
Ra + b Rb + a Rc + a
Rb + Rc Ra + Rc Ra + Rb calculates time varying magnetic fields in a frequency domain
Rc N  N LVb Rb N  N HVc is used to obtain lumped parameters in steady state. Energy,
L12 =  LVa , L16 =  LVa , (18)
Ra + Rc R + Ra  Rc Rb + Rc R + Rb  Rc torques, forces and inductances can be calculated from basic
Ra + Rc Rb + Rc field quantities such as the magnetic field and the magnetic
b a

Rc N  N LVb Ra N  N HVc scalar potential. The results obtained from this solution and
L21 =  LVa , L26 =  LVb analytical results are given comparatively in the Table 5. For
Rb + Rc R + bR  Rc Ra + Rc R + Ra  Rc
a
Rb + Rc
b
Ra + Rc instance, self-inductance L11 (LVa, LVa) was calculated as
follows,
Also mutual inductance of windings can be calculated by
2 2
the coupling coefficient between each phase and windings LV
N N
LV
[20]. The calculation of magnetization and leakage inductance L11 = =
R R 1 l l
using magnetic energy (W) stored in the windings and the gap R + b c  (l + b )
is most accurate. Using Ampere’s law the magnetization a R +R A l +l
b c b
inductance (Lm) can be expressed as follows [37];
402
=
Bcore 1 1.216  2.716
N LV  I m = l (19)  (2.716 + )
0 r −3
 10  0.057 1.216 + 2.716
= 54.22mH
0   r
Bcore =  N LV  I m (20) R1 ɪ2ʹ R2
l Lσ1 + + Lσ2 +
+
ɪ1 ɪm ɪ2
V1 Lm E1 E2 V2 RL
1 1
W= Lm  I m2 =  H  B  dv (21)
2 2v - - - -

Lm I m2 1 Bcore
2 Figure 5. Lumped model of transformer [36].
= V
2 2 0r
(22) Table 5. Lumped parameters of designed transformer.
1   r
= ( 0 N LV I m ) 2 l A Parameters FEM Analytical
0  r l
L11 (LVa, LVa) 54.394 mH 54.22 mH
L22 (LVb, LVb) 72.871 mH 72.623 mH
2
N LV  0   r  A
Lm = (23) L33 (LVc, LVc) 54.389 mH 54.22 mH
l
L44 (HVa, HVa) 53.924 H 53.799 H
L55 (HVb, HVb) 72.289 H 72.102 H
Where, Im is magnetization current and can be calculated
L66 (HVc, HVc) 53.929 H 53.799 H
by ILV - IHV / (turn ratio), Bcore is magnetic flux density of core,
ℓɸ is magnetic path length of core. Then leakage or short circuit L12 (LVa, LVb) 35.842 mH 35.674 mH
inductance (Lσ) can be derived in similar approach like L13 (LVa, LVc) 17.243 mH 17.113 mH
magnetization inductance applying flux diagram as shown Fig L14 (LVa, HVa) 1.71 H 1.706 H
5b as follows;
L15 (LVa, HVb) 1.13 H 1.124 H

5
 L16 (LVa, HVc) 0.543 H 0.528 H • E1=Vpeak*(1-exp(-50t))*cos(2*pi*50t)
L23 (LVb, LVc) 35.844 mH 35.657 mH • E2=Vpeak*(1-exp(-50t))*cos(2*pi*50t+(2/3*pi))
L24 (LVb, HVa) 1.129 H 1.12 H • E3=Vpeak*(1-exp(-50t))*cos(2*pi*50t+(4/3*pi))
L25 (LVb, HVb) 2.293 H 2.287 H Table 6. Simulation Parameters
L26 (LVb, HVc) 1.13 H 1.12 H
Simulation Parameters
Lσ (LVa) 0.12 mH 0.13 mH
Power 3.8 MVA
Lσ (LVb) 0.091 mH 0.097 mH
Voltage 690/36 kV
Lσ (HVa) 0.049 H 0.05 H
Frequency 50 Hz
Lσ (HVb) 0.0457 H 0.0478 H
Load-1 No load
Lm (LVa) 54.275 mH 54.148 mH
Load-2 (R) 354Ω
Lm (LVb) 72.779 mH 72.589 mH Scenario Load-3 (RL) 283Ω-0.68H
Resistance R1=R2=R3 0.697 mΩ 0.72 mΩ
Resistance R4=R5=R6 1.15 Ω 1.22 mΩ Load-4 (variable) 250Ω-400Ω-600Ω-100Ω

It is clear from Table 5 there is a symmetry between the In Figure 7 variable load used in simulation study and its
phase A and B, also there is a natural asymmetry of phase B. change time is given. At the beginning load is 250 Ω, then it is
Result shows that analytical method is in good agreement with changed to 400 Ω at 0.04s and 600 Ω at 0.08s then to 100 Ω at
the FEM. 0.142s.

3. Co-simulation study of the designed

transformer
The design and validation of electrical machines requires
complex processes. This is expected to be an expensive and
time consuming process. Accordingly, any simulation and
analysis model is required to be up to this case. In this section,
co-simulation study is realized by using ANSYS Maxwell and
ANSYS Simplorer software. Direct and indirect coupling are
two basic co-simulation approaches to couple electromagnetic
fields with circuits. In this study the direct coupling approach
where Maxwell 3D FE model can be solved transiently with Figure 7. Variable load used in simulation.
circuit model is used [38]. It offers a good solution to have
extensive data related to the behavior of transformer in 3.1. Flux Density
different operational conditions.
The core flux density can be expressed as follows [18, 39]:
The 3D FE model of transformer designed in section 2, is
placed in the circuit simulation model to analyze its operation 1
t

characteristics under different load conditions as shown in B=

N s  Ae
 v ( )  d  (25)
Figure 6. It is seen that the transformer is connected as ∆-Y 0

connection. Also, R1, R2, R3, R4, R5, R6 are the winding
resistance and R7, R8, R9 are load. In Table 6, simulation Where, v is secondary winding voltage, Ns is the number of
parameters and scenario are given. sense winding turns and Ae is the effective cross section of
core.
E1 +
The magnetic field is mainly affected by ferromagnetic
RL3
R1 R4 +
A

W
+
A

W
+

material with high relative permeability [39]. So M270-35A

l_L
V R2 WindingLV_B_in WindingLV_B_out
r_L

WindingLV_A_in V
E2 WindingLV_A_out
WindingLV_C_in WindingLV_C_out

(M19) has high permeability is chosen. In Figure 8 magnetic

l_L
A

r_L
0
R3 WindingHV_B_in WindingHV_B_out R5
WindingHV_A_in WindingHV_A_out
A

flux density of the core is given at full load that is 354Ω by

E3 WindingHV_C_in WindingHV_C_out
r_L l_L
0
A

FEA1
A

0
R6
Finite Element Analysis (FEA).
Figure 6. Simulation circuit consisting of co-simulation.

A voltmeter, ammeter, wattmeter and load bank are

connected at the output terminals of HV windings which is
delta-connected. Input terminals of LV windings are supplied
with a 3-phase, 563.3 V (Vpeak), 50 Hz voltage sources is star-
connected. At first, the 3-phase input voltage waveforms are
obtained by variation of phase shifting taps and an
exponentially increasing voltage source has been applied to a) b)
eliminate high inrush currents and a long simulation time as
follows;

6
 c) d)
Figure 8. Magnetic flux density of core at, (a) no load; (b)
full ohmic load; (c) RL load; (d) variable load.
The flux density distributions in the whole section of the
core (Figure 8) is obtained at 178 ms. It is seen by Figure 8 that
magnetic flux density of the core is under the saturation limit
(1.7 T) convenient to the design in section 2. Center leg of the
transformer is close to the maximum of 1.61T magnetic flux
density for rated voltage with full ohmic 354Ω load as shown
Figure 8b. Thereby, the hysteresis losses of the transformer is
forecasted to be very low.
3.2. Losses of Designed Transformer
The specification of losses in a transformer is one of the
important assignment that must be fulfilled during the
electromagnetic analysis [40]. Using 3D FEM model for the
electromagnetic analysis of transformers provides to obtain
numerical values of losses [41, 42]. Determination of accurate
data for B-P Curve of the electrical steel material has distinct
effect on the accuracy of this analysis. So the accurate data
provided by the manufacturers of materials are entered as
shown Figure 3.
The total loss of transformer mainly comprises of copper
loss (winding) and core loss. The core loss essentially involves
hysteresis losses, eddy current losses and additional losses [1,
40, 43]. The core loss is expressed in the frequency domain
[41, 42] under sinusoidal flux conditions as follows:
P = Kh Bmax
2
f + Kc ( Bmax f )2 + Ke ( Bmax f )1.5 (26)
Where, Kh, Kc and Ke are the hysteresis, eddy and
additional loss coefficient respectively, Bmax is the maximum
amplitude of the flux density and f is the frequency. The copper
loss or stranded loss is resistive loss in a 2D or 3D volume in
windings of which has multi-turn coils and stranded type are
determined as follows:
1
 V
Pst =  J 2  dV (27)
Where, σ is electrical conductivity, J is current density and
V is volume of winding. Core losses consisting of hysteresis
and eddy losses of the transformer is also so important for the
efficiency of transformer. In Figure 9 core losses are given
with respect to the different load conditions.
7
Figure 9. Core losses of M270-35A (M19) core, (a) no load;
(b) full ohmic load; (c) RL load; (d) variable load.
It is seen that average core losses are 5.23 kW, 5.18 kW
and 4.98 kW at no load, full load and RL load, respectively. At
variable load in Figure 9d, core loss is also around 4.86 kW.
Core loss is called a no-load loss of electrical machine.
Although it considered to be constant, it may slightly vary
depend on voltage and frequency for different operational
conditions as shown in Figure 9 [1]. It is clear from Figure 9
that core loss decrease in voltage decreases for different load
conditions.
Transient solution for stranded loss of the transformer is
given in Figure 10. These transient solutions is carried out
within 0.002 s steps between 0-0.2 s for achieving accuracy in
results. It can be observed that the stranded loss has reached
steady state at 100 msec. It is seen that stranded losses are 17
kW, 14.85 kW for full load and RL load respectively. And at
variable load in Figure 10d, stranded loss is also around 69.89
kW. it is especially seen that the stranded loss increases where
the load value is unexpectedly increased at 142 ms.
Figure 10. Stranded loss of transformer, (a) no load ;(b) full
ohmic load; (c) RL load; (d) variable load.
3.3. Performance of Designed Transformer
In order to observe HV and LV windings voltages, their
harmonic spectrums, under different load conditions including
ohmic and inductive loads, a 3D FEM coupled circuit model
is established as shown Figure 6 [24]. In Figure 11 phase
voltages of secondary windings of transformer that is HV
windings namely induced voltages is given by different load
conditions.
 Figure 12. HV windings phase currents, (a) no load; (b) full
ohmic load; (c) RL load; (d) variable load.

On the other hand, harmonic spectrum analysis for each

Figure 11. HV windings induced voltages, (a) no load; (b)
full ohmic load; (c) RL load; (d) variable load.
induced phase voltages as shown in Figure 13, and the total
harmonic distortion (THD)’s is 2.58 %, 2.87% and 1.15% for
each phase, respectively. When the FFT chart of induced HV
voltage is investigated, it is clear that the inductive load
increases distortion of sine wave compared to the ohmic load
(Figure 13b and Figure 13c).

It is seen in Figure 11 a), b), c) and d) that induced voltages

are sinusoidal with small unbalanced conditions, some notches
and voltage drop because of over loading, respectively.
Besides, HV windings phase currents are given in Figure 12
with different load conditions, full load, full RL load, variable
load. It is possible to assert that the transformer is giving a
proper reaction, especially where the load value is abruptly
increased. Some fluctuations have been observed owing to fact
that sudden changes in load.

8
 Figure 14. LV windings phase voltages, (a) no load; (b) full
ohmic load; (c) RL load; (d) variable load.

In Figure 15 transformer performance characteristics are

given under different load conditions, no load, full load, full
RL load, variable load. In Figure 15e the efficiency curve of
different load conditions (no load, %25 load, %50 load, %100
load and %125 load) including ohmic, and inductive loads are
given. The efficiency curve shows that the efficiency of the
transformer increases by 92% - 98.27% up to the rated. The
efficiency of the transformer at variable load is 96.59% on
average. So, the trend of voltage, current, power and efficiency
as a transformer performance show good agreement. So it is
easily applicable for an on-grid operating system of wind
turbine.

Figure 13. HV windings induced voltages harmonic

spectrum, (a) no load; (b) full ohmic load; (c) RL load; (d)
variable load.

LV windings phase voltages are also given in Figure 14

under different load conditions.

9
 Figure 15. Transformer performance, (a) no load; (b) full
ohmic load; (c) RL load; (d) variable load; (e) efficiency
curves
To conduct inrush analysis primary windings (LV
windings) are set at rated conditions and fed through the rated
voltage in a coupled external circuit. Then secondary windings
(HV windings) are open circuited. In the second step,
exponentially increasing voltage source is removed in order to
see the effects of the inrush current as follows;
Voltage
- % 1.12 %5 -
regulation
In addition, all of the performance values are summarized
at Table 7. It shows that designed transformer meets the
demand for grid. It provides pure sinusoidal voltage and
current where the grid conditions change. Especially at
overload the efficiency of transformer is about % 98.2.
3.4. Coupled Electromagnetic-Thermal Analysis

• E1=Vpeak*cos(2*pi*50t) In Figure 17, a multiphysics solution model of coupled

• E2=Vpeak*cos(2*pi*50t+(2/3*pi)) electromagnetic and thermal analysis is given. In this model,
• E3=Vpeak*cos(2*pi*50t+(4/3*pi)) the temperature dependence of the material properties on both
the thermal side and the electromagnetic side should be taken
into account and the electrical and mechanical properties of the
Consequently, quantities of interest which are inrush
materials should be defined. First 3D electromagnetic model
transient current of transformer for time duration of 1s, shown
determines core and winding losses, then losses are directly
in Figure 16. The peak value of inrush current culminates 9
coupled into thermal simulation as the thermal load in order to
times the transformer at nominal load current. The current
obtain temperature distribution. The last, resulting temperature
becomes steady-state condition after 0.6 seconds. Power
is coupled as feedback into electromagnetic side to change
capacitors used in power systems cause this transient to
permeability and conductivity of material.
increase. To protect transformers from the effects of this inrush
current differential relays are used.

Figure 17. Multiphysics solution model

Losses are given Table 8 imported into thermal simulation as

the thermal load in order to obtain temperature distribution. A
scaling factor enclose to 1 means proper network and loss
mapping from magnetic field solution to steady-state thermal
setup.

Table 8. Imported loss density with scaling

Object Total Loss Scaling Factor
Core 4496.23W 1.00048
Figure 16. Inrush currents, a) phase currents, b) three phase
HV_C 2250.9W 0.984874
currents.
LV_C 1374.15W 0.97623
HV_A 2240.38W 0.989194
Table 7. Performance of designed Transformer
HV_B 2243.97W 0.983994
Value
LV_A 1383.16W 0.982679
Parameters R R-L Variable LV_B 1371.61W 0.989328
No load
load(rated) load(rated) load(avg)

Output power - 3.84 MW 2.73 MW 4.98 MW

HV Induced 21.81
21.48 kV 20.35 kV 19.26 kV
voltage (ph) kV
LV Induced 693.33
689.2V 690.46 V 680 V
voltage (ph) V
Load current - 60.1 A 56.16 A 195.49 A
Terminal voltage 37.49
36.85 kV 34.98 kV 33.84 kV
(ph to ph) kV
Frequency 50 Hz 50 Hz 50 Hz 50 Hz

Efficiency - % 98.27 % 98.6 % 96.6

10

Figure 18. Temperature distribution of transformer
Figure 18 shows the temperature distribution of the all
body of transformer. The temperature of the core limbs which
are in direct contact with the windings is higher than that of
the core back. As expected, the maximum temperature is 108
°C in the LV winding and 106 °C in the HV winding. The
average temperature on the whole body is 93.23 °C.
Fan cooling systems can be employed with natural
convection in order to decrease temperature. Natural
convection is a cheap and suitable way for heat transfer. It is
commonly used in the dry type power transformers.
4. Conclusion
In this paper, 3.8 MVA power, 690V/36 kV three phase
transformer design for wind turbine is realized. After
designing the transformer, its lumped parameters analytically
and by using eddy current solver. Thanks to the
electromagnetic field, circuit and thermal model including
three different software Ansys Maxwell, Simplorer and
Mechanical used in this paper, transformer core losses,
harmonic spectrums under different load conditions and
thermal distribution of the all body are measured. Transient
solutions in co-simulation are carried out within 0.2 ms steps
between 0-200 ms in order to obtain more accurate results.
It is shown by this paper that the transformer designed has
low core loss values with different load conditions that is 5.23
kW, 5.18 kW, 4.98 kW and 4.86 kW. Besides, under different
load conditions, harmonic spectrum of the secondary (HV)
windings voltage are measured as 2.58%, 2.87%, 1.15% that
is lower than the values stated in standard IEC and resulting
phase currents are obtained sinusoidal. The efficiency, voltage
regulation and avarage tempereture of the proposed
transformer are about %99, %1.12 and 93.23 °C respectively
at full load. So it is quite good and acceptable. Furthermore, it
is also shown that the co-simulation technique presented in this
paper for wind turbine transformer works properly.
It is important to realize that a finite element model cannot
consider all of the physical core loss effects such as
mechanical stress on laminations and edge burr losses. Hence
as a future work, a FEM multiphysics simulation structure will
be used to couple 3D FEM electromagnetic, steady-state
thermal, and structural analyses. This enables to import core
and stranded losses that is computed in the electromagnetic
field into the thermal analysis module and then structural
analysis module to determine steady-state temperatures and
11
deformations.
Ethical Approval
Not applicable
Competing interests
The author has no conflict of interest.
Authors' contributions
Y.C conceived and designed the analysis. E.S developed the
theory and performed the matrix computations. All authors
contributed to perform of co-simulation or multiphysics
solution. All authors wrote the main manuscript text.
Funding
There is no funding
Availability of data and materials
Not applicable
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