PTC Slides 1

Elektriseadmete raalprojekteerimise kursuse kodune
ettevalmistus ja slaidid: trafod
Metoodiline juhend üliõpilastele ja juhendajatele
Home assignments and slides in course on Numerical

modelling and design of electrical devices: transformers
Guide for students and supervisors
Project 1.0101-0278
Application of interdisciplinary and international team

and project based learning in Master Studies
IN 557
PROJECT 1.0101-0278
APPLICATION OF INTERDISCIPLINARY AND INTERNATIONAL TEAM
AND PROJECT BASED LEARNING IN MASTER STUDIES
IN 557
DESIGN, OPTIMIZATION AND PROTOTYPING OF POWER

TRANSFORMERS
COURSE ORGANIZERS
Lecturing:
Avo Reinap e-mail: avo.reinap@iea.lth.se eSkype: avo.reinap
Rando Pikner e-mail: rando.pikner@ttu.ee
Prototyping:
Michael Schmelzer e-mail: michael@msbaltitrafo.ee
Rando Pikner e-mail: rando.pikner@ttu.ee
Main program coordinator at Tallinn University of Technology:
Juhan Laugis e-mail: laugis@cc.ttu.ee
COURSE PROGRAM
INDIVIDUAL PREPARATION
Home preparation + Webinars + Feedback
W Event Preparation
42 First contact via e-mail Engineering challenges: How do design a power
transformer? Prepare your individual work plan.
43 Correspondence via e-mail preparing Course compendium (a complementary material to
to hold a webinar classical text books) & Design specifications
44 Correspondence via e-mail or/and a Design model of a power transformer, parameterization,
webinar sensitivity, analytic vs numeric model
45 Correspondence via e-mail or/and a Transformer characteristics, sensitivity analysis and
webinar optimization
46 Correspondence via e-mail or/and a Starting a course report
webinar
TEAM WORK
Design refinement + Prototyping
W Time Weekday: Mon-Tue-Wed-Thu-Fri
47 08:00-09:30 Arrival & Design model Transformer (Theoretical)
Accom- of a power design with Preparations
10:00-11:30 modation transformer Transformer RALE for building
characteristics prototypes
12:00-13:30 Numeric field
modelling
14:00-15:30 Presentation of Optimization
preparations of a power
16:00-17:30 transformer
48 08:00-09:30 Arrival to Making Making Assembling Testing
Vändra windings windings and and testing
10:00-11:30 MS Balti Trafo core
12:00-13:30 (Practical)
Preparations
14:00-15:30 for building
16:00-17:30 prototypes Back to TUT
49 08:00-09:30 Handin report
Preparing for
10:00-11:30 Completing presentation Farewell
the course
12:00-13:30 report, Presentations
14:00-15:30 conclusions
16:00-17:30
W – week number
Course on Design, Optimization and Prototyping of Power Transformers 2006-10-19
Introduction to Individual Preparations
COURSE ON DESIGN, OPTIMIZATION AND PROTOTYPING OF POWER

TRANSFORMERS
This course is a part of the application of interdisciplinary and international team and project based learning in
master studies (Project 1.0101-0278).
OBJECTIVE
The purpose of this page is to give an overview of the course and the course program.
COURSE DESCRIPTION
The course focuses on electromagnetical energy conversion that takes place in a power transformer. The course
is held in two parts, where the first part concentrates to an individual preparation and an actual teamwork takes
place in the second part. The importance of the individual studies is to become acquainted with or/and to recall
knowledge on
electromagnetic field theory,
magnetic materials and magnetic circuits,
circuit analysis,
phasor domain, single and 3-phase ac circuits.
During the preparations students will add to their knowledge-base in the fundamentals of electrical and
computer engineering, knowledge about the solution procedures and computer utilization for solving practical
applications related to electric and magnetic circuits, single and three-phase circuits, energy conversion principles,
and basics of the transformer characteristics and operation. By solving project task, which is to design a power
transformer and later actually to build it, possible solutions must be analyzed and among them the best solutions
are to be selected. Therefore the theoretical preparations focus on
establishing a good design model and
using the model to find an optimal design.
The pre-established skills of problem solving and critical thinking are vital in the teamwork sessions when
completing the design and making the actual prototype. During the preparation period there are weekly
homework assignments that suppose to be handed in electronically before the next assignment will be
announced. These assignments suppose to indicate engineer’s respectability and writing skills in clean organized
presentation and clear decisions explanation manner. Later these assignments can efficiently be used to complete
the individual course report.
COURSE PROGRAM – INDIVIDUAL PREPARATION

During the next four weeks four home assignments will be given
drafting – gained ideas of how to design and to optimise a transformer and the actual time planning for
the individual progress (W43),
Design model – starting to formulate a design model for a power transformer i.e. the mathematical
description of the geometrical object and physical process (W44),
Analysis – the design parameter, number of phases (Nph), could be easily changed from 1 to 3 and
backwards, investigate the sensitivity of the design model (W45),
Optimization – find the set of design parameters that gives the lowest weight, the losses, the cost of the
transformer (W46).
It is expected that the assignment will be handed in on Thursdays (in the week shown in parentheses) for the
further encouragements.
Home Assignment 2 - model
HOME ASSIGNMENT 2
This is a home assignment in the course on design, optimization and prototyping of power transformers.
OBJECTIVE
The purpose of the home assignment is to start building a mathematical model of an electromagnetic
energy converter – a transformer.
MODEL
The second assignment is a continuation to the first assignment that first of all bases on designer’s
creativity. Concerning to the first home assignment, the course supervisor would like to know how a course
participant interprets the word/action 'design' and 'optimization', and what software she/he thinks is
suitable to develop such an environment where design and optimization of a power transformer is possible.
So the main goal of the second home assignment is to start completing a mathematical design model of a
transformer. To design an electrical device is an engineering challenge that usually includes the following
steps: physical understanding, mathematical modelling, analysis, synthesis and optimization. The course
material that could help you with the design process focused on transformers is not distributed yet. The
reason for that is to encourage a course participant to think freely and creatively.
The task is to establish a mathematic description of a geometrical object and a physical process of an
electromagnetic transformer. The parameters that specify the physical process are:
Rated primary (phase) voltage Up1=230 V,
Rated apparent power a) 1-φ S=1000 VA, b) 3-φ S=250 VA,
Rated secondary (phase) voltage Up2=48 V,
Full load voltage regulation sUp2=20%,
Winding temperature class B or F,
Natural cooling conditions aCu=8.9 W/Km2, aFe=21.3 W/Km2, Tamb=40OC,
Number of phases (φ) Nph=1 and Nph=3.
Please feel creative when designing a transformer start from establishing a good physical understanding
then try to interpret the physics through mathematic. I would like to see your thoughts and progress in a
couple of pages on Thursday 2nd of November!
Good Luck!
Avo R
Do you feel already hopeless? There will be a course material on numerical modelling and design of
electrical devices. There you could see that your transformer model could be analytical or/and numerical.
Apart from that there you can read my interpretation to the first home assignment about design and
optimization. I prefer freeware to carry out the design task FEMM and Mirage for numeric field
computation and SciLab for the rest. Actually in Tallinn we are going to use Matlab and this considers the
‘rest’ – analytical modelling, optimization and result visualisation. SciLab is quite the same as Matlab,
nevertheless it is free and you can find the freeware by help of google.
Home Assignment 3 - analysis
HOME ASSIGNMENT 3
OBJECTIVE
The purpose of the home assignment is to start analysing a transformer with the established mathematical
model of an electromagnetic energy converter.
ANALYSIS
The third assignment is a continuation to the second one as the second assignment was a ‘natural’
continuation to the first assignment. The assignments are focused towards participants’ professionalism on
electrical engineering. The output from the second home assignment supposes to be a mathematic model
that describes a geometrical object and a physical process of an electromagnetic transformer. The model
consists of (design) parameters that specify the physical process related to the constructional geometry. The
main purpose of this home assignment is to analyse the behaviour of the model and to see if it gives
reasonable results. In addition
Change design parameter Nph from 1 to 3 and make it possible that you can run both models
easily,
Introduce a parameter change in geometry and study the influence to transformer performance,
losses, weight of copper and iron, etc,
Consider losses and magnetic saturation in the transformer model(s).
The physical properties of electromagnetic steel are attached to this document. Take material data
(Surahammars Bruks AB) suitable for you. One way or another, the material input will be later different, i.e.
given by MS Balti Trafo, try to introduce flexibility when making changes in model. Please feel creative
when starting to use your model for analyses. Soon it is day ready (the fourth assignment) for synthesis and
optimization. I would like to see your thoughts and progress in a couple of pages on Thursday 9nd of
November!
Good Luck!
Avo R
Do you feel depressed? There will be an half of course material on design, optimization and prototyping of
a power transformer. There you could see my interpretation of geometrical modelling and the equation
system describing the transformer in a fixed frequency frame. This could be a complementary material to
yours and the rest of references you have found so far.
Home Assignment 4 - synthesis
HOME ASSIGNMENT 4
OBJECTIVE
The purpose of the home assignment is to complete the home preparation period by synthesising a
transformer.
SYNTHESIS
The fourth (last) assignment is a continuation to the sequence of the home assignments. The outcome of
this homework is a transformer design that is “ready” for prototyping. A transformer construction can be
proposed on the basis of the mathematic model that describes a geometrical object and a physical process
of an electromagnetic transformer. Synthesis can be seen as an inversion to analysis. According to the
performance requirements, which were described in the second home assignment, the transformer
geometry has to be proposed. An additional design table will be provided where you specify the
transformers that you have been designing. Fill as many cells in the table as you are able. The data will be
summoned up in common table for comparison and presented in the opening session. In addition please be
ready to make presentation, where
On a couple of slides you will give short overview of yourself, your curriculum and university,
There suppose to be one slide per home assignment, where you try to formulate the essence of
your thoughts and achievements,
At least one slide about your expectations from the course.
See you in Tallinn on Monday 20th of November!
Good Luck!
Avo R
It is too late to be depressed. As far I have seen you have already made a good progress, you are well
prepared and have some ideas about:
• What is design and which are the possible software to carry out the design task,
• How the transformer works and how this can be described mathematically,
• The specification of the transformers that we are going to work on,
I think this is a good starting point for teamwork!
Home Assignment 4 - synthesis
A single phase A three-phase

quantity symbol unit
transformer transformer
rated apparent power S VA 1000 250
rated primary voltage (phase, rms value) Up1 V 230 230
rated secondary voltage (phase, rms value) Up2 V 48 48
full load voltage regulation sUp2 % 20 20
type of transformer - -
winding connection Δ/Y
height of transformer Htr mm
length of transformer Ltr mm
width of transformer Wtr mm
maximum flux density in the core Bc T
2
maximum current density in the primary winding Jc1 A/mm
2
maximum current density in the secondary winding Jc2 A/mm
the induced voltage per phase at 50Hz Ep V
2
cross-section area of primary electric circuit A1 mm
2
cross-section area of secondary electric circuit A2 mm
2
cross-section area of magnetic circuit (core) Ac mm
copper filling factor in the primary winding Kf1 %
copper filling factor in the secondary winding Kf2 %
height of primary electric circuit (winding) Hw1 mm
height of secondary electric circuit (winding) Hw2 mm
Length of primary electric circuit (winding) Lw1 mm
length of secondary electric circuit (winding) Lw2 mm
the thickness of main insulation insl mm
number of turns in primary winding N1 turns
number of turns in secondary winding N2 turns
turn length of copper wire in primary winding Lc1 mm
turn length of copper wire in secondary winding Lc2 mm
diameter of copper wire in primary winding Dc1 mm
diameter of copper wire in secondary winding Dc2 mm
phase current rms value in primary winding Is1 A
phase current rms value in secondary winding Is2 A
the phase resistance in primary winding R1 Ohm
the phase resistance in secondary winding R2 Ohm
the phase inductance in primary winding L1 mH
the phase inductance in secondary winding L2 mH
thermal limit to the primary current Ith1 A
thermal limit to the secondary current Ith2 A
hot-spot temperature in primary winding ϑc1 °C
hot-spot temperature in secondary winding ϑc2 °C
copper losses Pcu W
ferrous losses Pfe W
2
the losses per cooling surface QP W/m
weight of core Mrc Kg
weight of stator core Msc Kg
weight of copper Mcu Kg
Welcome!
Course on Design, Optimization and

Prototyping of a Power Transformer
Program structure
• Project 1.0101-0278
• Application of interdisciplinary and
international team and project based learning
in Master Studies
• IN 557
Department of Electrical Drives and Power Electronics
• Courses on Industrial automation, electrical

drives and power electronics, Computer aided
design
• Course on Design, Optimization and Prototyping
of a Power Transformer
Course on design, optimization and prototyping of power transformers
Course structure
• Individual preparation period (5 weeks)
– meaning of design and optimization,
– design model – focus on a 1φ transformer
– Parameterisation and analysis – switch from 1φ to 3φ
– Synthesis and result presentation
• Team work sessions (2 weeks)

– Design and optimization of two power transformers
– Prototyping of the designed transformers
• Design and course evaluation (2 days)
Individual preparations
• Improve one’s knowledge-base for the further
efficient collaboration,
• Establish a good contact with each course
participant in order to support the improvements,
• Intensive program, communication via possible
media simultaneously,

Course program W47
Monday Tuesday Wednesday Thursday Friday
20-NOV-06 21-NOV-06 22-NOV-06 23-NOV-06 24-NOV-06
08:00 E31 Design E41 Design
09:30 with RALE specification
10:00 E11 Design E21 Cha-
11:30 models racteristics
12:00 E32 Design E42 Design

13:30 comparison specification
14:00 Course start E12 FE E22 Optimi-
15:30 modelling zation
16:00 Intro to
17:30 software
Course program W48

27-NOV-06 28-NOV-06 29-NOV-06 30-NOV-06 01-DEC-06
08:00 Arrival to P2 Making P3 Making P4 P5 Testing
09:30 Vändra the win- the win- Assembling
10:00 MS Balti dings and dings and and testing
11:30 Trafo the core the core
12:00 P1 Practical
13:30 preparations
14:00 for building Back to
15:30 the prototy- Talinn
pes
16:00
17:30

Course program W49
04-DEC-06 05-DEC-06 06-DEC-06 07-DEC-06 08-DEC-06
08:00 C3 handing Farewell
09:30 in course
10:00 C1 Post report
11:30 analysis
12:00 C4 Presen-
13:30 tations,
14:00 C2 concluding
15:30 Reporting, session
16:00 completing Farewell
17:30 course doc
Course Participants
• Piotr from Gdansk
• Edgars from Riga
• Andrius from Vilnius
• Roman from Tallinn
• Karl from Tallinn

Introduction to design and
design environment
Course on numerical modelling
and design of electrical devices
Development
real device modelling mathematical model of
the device
measurement computer simulation theory
experimental data computed data theoretical prediction

comparison comparison
verification of the model verification of the model

by simulation by theory
• Theory, experiment and simulation employed to

understand the physical reality and put it into practice
Design
• Design is a process of development
• In this course the development is focused on the field of
electrical engineering – a power transformer
• Design based on a model – description of system and
structure, that handles the complexity of PDE
• Designer seeks for / explores the optimal combination of

structure and functionality of a device
• Cost efficient solution is usually more crucial than the
technically optimal device
• Design will always remain stimulating and challenging
engineering profession
Computer Aided Design

Conceive Design
Develop Manufacture
CAM
CAD Tool design
IDEAS Detailed device Drawings
Concept design modelling
Validate
Product layout
Analysis
Requirements
CAE
• Efficient use of computation power and information

• CAD, CAE, CAM

Idea
• Knowledge – understanding of something
• Intention – purpose of doing something
• Principle – belief how something (is or) should be
• Suggestion – a plan for possible course of action
• Software suitable for design, any idea?

• What do design? no idea!?
Design environment
• The design environment is
established in Matlab APPROXIMATE
DESIGN MODEL
– Approximate design model
– Analysis and optimization
– Visualization and administration
• Finite element modelling is
performed by freeware NUMERICAL

ANALYSIS
OPTIMIZATION
– Mirage – heat transfer

– FEMM – magnetics

Design task
• Find a minimal cost of a power transformer
• Power transfer
– A single-phase 1000VA
– A three-phase 250VA
– At natural cooling conditions
• Power conditioning
– Line voltage 230V / 48V
– Voltage regulation 20%
• Laminations: M330-50A or M530-50A,
• Winding insulation class, F or B
Electromagnetic circuit
m-core phi
∫ Hdl = ∫ J dA → ∑ Hdl = JA
C A
slot k fill = NI
+N·I -N·I Bm Bg Bb
H m l m + H g l g + H b lb = lm + lg + lb = NI
μ0 μ m μ0 μ0 μb
lm lg lb
φm + φg + φb = NI → φ ∑ ℜ = NI
air-gap Fn μ 0 μ m Am μ 0 Ag μ 0 μb Ab
1
iron bar
Fn =
2μ0
∑A B
g
2
g
• Ampere’s circuital law applied to magnetic circuit

• Maxwell stress concept – forces in magnetic field

Geometry parameterization
wsc
wsc
ins wsp =
Ns +1− Ks
wst
hsc
wst = wsp (1 − K s )
wss = wsp ⋅ K s
hst = hsc − wst
g
wst
Aslot = (hst − 2ins )(wss − 2ins )
• Magnetic circuit is described by parameters: proportions,

dimensions and numbers
• Parametric geometry input in electromagnetic circuit
calculations
Heat transfer
qn=h(ϑ-ϑamb)
P
ϑ m = P ⋅ Rth =
A ⋅α 2
V ⋅ ρ ⋅c
τ th = C th ⋅ Rth =
A ⋅α 2
J2ρKf J2ρKf
τ
⎛ − th ⎞
+ (ϑ m − ϑamb ) ⋅ ⎜1 − e t
ϑ = ϑamb ⎜ ⎟
⎟
⎝ ⎠
• Fourier’s heat conduction in the materials

• Newton’s convection boundary conditions

Electromagnetic circuit calculations
• Methods
– Simple approach
– Equivalent circuit method (Magnetic EC, Thermal EC
1D elements describing 3D object)
– Finite element method (multiphysics 2D, 3D)

• Tools
– Matlab (Design environment)
– FEMM (Magnetism) , Mirage (Heat transfer)
Example in Matlab
region area 14.0
4.5
(0.0,4.0) (5.0,4.0)
4
3.5
3
(1.0,3.0) (2.0,3.0) (3.0,3.0) (4.0,3.0)
% Matlab script for m-core
2.5 x=[0 1 1 2 2 3 3 4 4 5 5 0 0];
2 y=[0 0 3 3 0 0 3 3 0 0 4 4 0];
1.5
figure(1); plot(x,y)
0.5
A=polyarea(x,y);
0
(0.0,0.0) (1.0,0.0) (2.0,0.0) (3.0,0.0) (4.0,0.0) (5.0,0.0) title(['region area ' …
-0.5
0 1 2 3 4 5
num2str(A,'%1.1f')])
• M-core dimensions, width 5.0 cm, height 4.0 cm

• M-core proportions, slot width = Ks*tooth pitch

FEMM Pre-Processor
• Drawing the endpoints of the
lines and arc segments for a
region,
• Connecting the endpoints with
either line segments or arc
segments to complete the
region,
• Defining material properties

and mesh sizing for each
region,
• Specifying boundary
conditions on the outer edges
of the geometry.
FEMM Post-Processor
• Flux lines show magnetic
coupling between the
magnetic conductive parts
• Flux density indicate magnetic
loading
• Generally the forces are
calculated by using weighted

Maxwell’s stress tensor
• Flux linkage can be obtained
from circuit-data

FEMM and LUA Script
• Femm functions are called by LUA Script
• Scripting is similar to Matlab, it is possible to create user-
independent calculation loop
Summary
• Course structure and plan
• Course participants
• Introduction to design and design environment
• Examples:
– Design of electromagnetic/mechanic energy

converter,
– Intro to Matlab
– Intro to FEMM/Mirage

Model

Design model and design process

• Multiple files used in Matlab
– Listing ‘all’ equations determining the transformer
behaviour
– Selecting design variables and acceptable limits
– Setting performance criteria and comparison
• Design process
– Select random values in order to study the ‘limits’ of
the model
– Evaluates device behaviour and checks for feasibility
– Compares to other designs and stores best designs
Electromagnetic circuit calculations
• Methods
– Simple approach
– Equivalent circuit method (Magnetic EC, Thermal EC
1D elements describing 3D object)
– Finite element method (multiphysics 2D, 3D)

• Tools
– Matlab (Design environment)
– FEMM (Magnetism) , Mirage (Heat transfer)
Equivalent circuit relations

Electrical Magnetic Thermal
Relation
circuit circuit circuit
Potential U=E·l N·I=H·l ϑ=G·l
Flow I=J·A Φ=B·A Q=q·A

Resistive
R=1/γ·l/A R=1/μ·l/A R=1/λ·l/A
element
Ohm’s Law U=I·R N·I=Φ·R ϑ=Q·R

Thermal circuit (A)
ϑ4
Gϑ34 • Node points i, Qi [W], ϑi [K]
ϑ3 1. Coil loss and temperature
Gϑ23 Gϑ13 2. Tooth loss and temperature
3. Yoke loss and temperature
4. Ambience temperature
ϑ2 ϑ1 • Thermal conductivity
Gϑ12
elements Gij [W/K]
– From coil to tooth G12
– From coil to yoke G12
– From tooth to yoke G23
– From yoke to ambience G34
Thermal circuit (B)

• Topology matrix • Circuit formulation
T(k, :) = element k nodei node j Gij Gϑ = Q

1 1 2 G12 G12 + G13 − G12 − G13 0 ϑ1 Q1
2 1 3 G13 − G12 G12 + G23 − G23 0 ϑ Q

T= ⋅ 2 = 2
3 2 3 G23 − G13 − G23 G13 + G23 + G34 − G34 ϑ3 Q3
4 3 4 G34 0 0 − G34 G34 ϑ4 0
ϑB − initially given
ϑ = G −1
N optimization
Course on design,
(Qprototyping
N and N − GofBpower B)
⋅ϑtransformers
Thermal design
• Good estimate of losses – the distribution of
heat sources
• Thermal characteristics of materials
• Heat dissipation – thermal circuit and cooling
system
• Thermal limits at cooling capability
Thermal limits
5
180 10
ϑambmax 15
160 Δϑallow ed
Δϑsafety 10
140
10 4
temperature ϑ [°C]
120 5 10
thermal life [h]
100 5 125
105
80 80
75
60 3
60 10
40
20 40 40 40 40 40 Class 200
Class 155
2
0 10
A E B F H 140 160 180 200 220 240 260 280
insulation classes temperature ϑ [°C]
• Insulation lifetime is shortened radically if temperature

exceeds the limit and that is due to accelerated oxidation
process in the insulation material.

Modeling a winding
λcond ⋅ λins
λeff =
λins ⋅ k f + λcond ⋅ (1 − k f )
L ⋅ (1 − k f ) L ⋅ (λins ⋅ k f + λcond ⋅ (1 − k f ))
L L⋅kf
= + =
λeff λcond λins λcond ⋅ λins
• Equivalent thermal conductivity of a winding is given by

the filling factor of the conductor strands (copper in this
example) and the thermal conductivity of the medium
between the conductor strands
Transient heat flow

l
ϑ ϑhot
A
Q P = QS + Q D
α1 ϑ1 dϑ ϑ
P = C th +
α2 ϑ2 dt Rth
ϑamb
QP QS QD dϑ
x P =V ⋅ ρ ⋅c + A ⋅α 2 ⋅ϑ
dt
P
• Steady state temperature ϑm = P ⋅ Rth =
A ⋅α 2
• Heating time constant V ⋅ ρ ⋅c
τ th = Cth ⋅ Rth =
• Temperature rise during the A ⋅α 2
transient heating ⎛ τ
− th ⎞
ϑ = ϑamb + (ϑm − ϑamb ) ⋅ ⎜⎜1 − e t ⎟
⎟
⎝ ⎠
Transport of heat
•Q - the required flow rate, m3/s, Ph -
Ph required cooling power, W, ρ - the density
Q=
ρ ⋅ c ⋅ Δϑ of the heat carrier, kg/m3, c - the specific
heat capacity, J/kg°C, Δϑ - the temperature
difference between incoming and outgoing
temperature °C
W
α = 5K 25 •Natural convection
K ⋅ m2
•Forced cooled plane surface by air speed
α = 7.8K 20 ⋅ v 0.6K0.78 v
Ploss kW •Empirical cooling capability
= 1K 2.5 2
Acool m
Heat sources and hot-spot

• Specific heat loss of electric
1 2
conductor depends on electric qe = J m ρ
loading and resistivity 2
• Specific heat loss of magnetic
conductor depends on magnetic 1 2 2
loading, speed and ‘conductivity’, m 2 Bmω k m
q =
• The temperature rise of a

‘conductor’ depends on the q d2
shape of the conductor and the
Δϑ =
2k g λ 4
thermal conductivity,

Winding losses
• Resistive loss – energy wasted due to a
material’s opposition to the flow of electric
current
• A current displacement effect – due to the
opposing induced currents
– Proximity effect
– Skin effect
Core losses
• The reactive power loss associated with energy stored in
the magnetic core of a transformer,
• The active power loss is due to hysteresis loss and eddy
current loss,
• Hysteresis loss – rate of change of energy used to affect
magnetic domain wall motion,

• Eddy-current loss (macro eddy currents) is due to
induced currents flowing in closed paths within magnetic
material,
• Anomalous loss (micro eddy currents) eddy current loss
due to magnetic domain wall motion
Core losses
8
7
• Specific losses approach
specific losses pc, [W/kg]
5 – Calculate Bm(x,y,z)
4
– Estimate pfe(Bm,freq)
3
2 • Loss formulas approach

– Calculate B(x,y,z,t)
1 M 330 - 50 A
M 530 - 50 A
0
0 0.5 1 1.5 2
7000
M 330 - 50 A
– Model (Steinmetz)
relative magnetic permeabilityμ, [-]
6000 M 530 - 50 A
5000
4000 pfe=ChBhf+CeB2f2+CaB1.5f1.5
3000
– Estimate pfe(B(t))
2000
1000
0
0 0.5 1 1.5 2
• Simultaneous electromagnetic
flux density B, [T]
and material modeling
Reduction of losses
• Electric conductor: reduce ρ(ϑ), reduce eddy
current effects (Litz wire, transposing, twisting,
etc), reduce current loading (bigger slot for the
same magneto-motive force)
• Magnetic conductor: Increase ρ(ϑ), reduce the
cross section area of electric conductor (thinner

lamination, iron powder, etc), reduce magnetic
loading

Magnetic circuit (A)
• Loaded transformer
φ2 – Source flux φ1,
– Linked flux φ2,
– Leakage flux φσ,
Gμ1 Gμσ Gμ2

u1 u2
i1N1 i2N2
φ1
Magnetic circuit (B)

• Short-circuited ideal
φ2
transformer
– R2=0Ω
– Ψ2=0Vs
– Lσ= Ψ1/i1
Gμ1 Gμσ Gμ2
• Short-circuited ideal
u1
transformer
i1N1 i2N2 – R2≠0Ω
– Ψ2=- Ψ20
φ1

Electric circuit (A)
• Complete equivalent circuit for a transformer
Electric circuit (B)

• Simplified equivalent circuit

Summary
• The model of a transformer can be established
either by starting from power transfer or power
conditioning requirement
• It is important to get a good understanding in
physics before formulating the problem in
(advanced) mathematics
Optimization

Construction of a transformer
• Intercoupled circuits: Electrical, magnetic and thermal
Parameterisation of construction
• Length of transformer (Ltr), thickness of insulation (ins)

and the geometrical proportions fully describes the
construction
Maximized cross-sections (A)
shell type core type
8
2
2
4
4
2
relative transformer height, kH [-]
2
4
2
6
6
4
2
4
2 4 2
2
8
8
14 12
8
6
10
6
10
6 4 2 4
2
14
0.5 0 0
0
12
10 810 6 4 2 2
0.25 4
0.25 0.5 1 2 4 8 0.25 0.5 1 2 4 8
relative transformer width, kW [-] relative transformer width, kW [-]
• The largest available cross-section area of electric and

the magnetic ‘conductor’
k t k f k l (1 − k s )k s
⎜ kW − kTW (1 − k s ) ⎟⎜ k H − kTH k s
Ae Am ⎛ ⎞⎛ ⎞
ltr k p = = ltr ⎟
Vtr 2⎜ Np ⎟⎜ Np ⎟
kW k H N p ⎝ ⎠⎝
⎠
Maximized cross-sections (B)

• The largest available cross-section area of electric and

the magnetic ‘conductor’

Power density of transformer
• Apparent power
1 1
S = U m I m = ω Bm J m Ae Am
2 2
• Transformed power density

S 1
= ω Bm J mltr k p
Vtr 2
Temperature rise in ‘conductor’

• Plate
d/2
ϑ=ϑs ϑ (x ) = ϑ (xs ) +
q
2λ x
(
⋅ xs − x 2
2
)
ϑ=ϑs
• Cylinder
0.5dmax Q=0
ϑ (r ) = ϑ (rs ) +
q
4λ r
(
⋅ rs − r 2
2
)
q,λ
• Temperature rise
Q=0 2
q d
0.5dmin Δϑ =
λ 4
2k gtransformers
Course on design, optimization and prototyping of power
Minimal temperature rise
shell type core type
8
2
4
4
2
024
6
2
relative transformer height, kH [-]
4
2
2
4
6
0 82 46
2
4
6
8 4
14
12
1 16
12
14
8
8 6
10 4 16
10
0.5 10 02 4 6 02
10
0.25
0.25 0.5 1 2 4 8 0.25 0.5 1 2 4 8
relative transformer width, kW [-] relative transformer width, kW [-]
• According to the same loss density (W/m3) and thermal

conductivity (W/mK)
Optimization example
9
• Find
11
maximum
6
5
8 7
9 8
power
6 10 transfer for a
7
given
1
10 12 1
11 13 15 2 2
3 3
geometry of
14
12
16 4 4 a transformer
5 • Use Matlab

Summary
• The example of the objective function of a
transformer is rather established according to
power transfer requirement and leaving the
power conditioning requirement for the
completion

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Elektriseadmete raalprojekteerimise kursuse kodune

ettevalmistus ja slaidid: trafod

Metoodiline juhend üliõpilastele ja juhendajatele

Home assignments and slides in course on Numerical

Guide for students and supervisors

Application of interdisciplinary and international team

DESIGN, OPTIMIZATION AND PROTOTYPING OF POWER

COURSE ON DESIGN, OPTIMIZATION AND PROTOTYPING OF POWER

COURSE PROGRAM – INDIVIDUAL PREPARATION

A single phase A three-phase

Course on Design, Optimization and

• Courses on Industrial automation, electrical

• Team work sessions (2 weeks)

Course on design, optimization and prototyping of power transformers

Course on design, optimization and prototyping of power transformers

12:00 E32 Design E42 Design

Course on design, optimization and prototyping of power transformers

Course program W48

Course on design, optimization and prototyping of power transformers

Course on design, optimization and prototyping of power transformers

• Karl from Tallinn

Course on design, optimization and prototyping of power transformers

measurement computer simulation theory

experimental data computed data theoretical prediction

verification of the model verification of the model

• Theory, experiment and simulation employed to

• Designer seeks for / explores the optimal combination of

Computer Aided Design

• Efficient use of computation power and information

Course on design, optimization and prototyping of power transformers

• Software suitable for design, any idea?

Course on design, optimization and prototyping of power transformers

performed by freeware NUMERICAL

– Mirage – heat transfer

Course on design, optimization and prototyping of power transformers

• Ampere’s circuital law applied to magnetic circuit

Course on design, optimization and prototyping of power transformers

• Magnetic circuit is described by parameters: proportions,

• Fourier’s heat conduction in the materials

Course on design, optimization and prototyping of power transformers

– Finite element method (multiphysics 2D, 3D)

Course on design, optimization and prototyping of power transformers

• M-core dimensions, width 5.0 cm, height 4.0 cm

Course on design, optimization and prototyping of power transformers

• Defining material properties

Course on design, optimization and prototyping of power transformers

calculated by using weighted

Course on design, optimization and prototyping of power transformers

Course on design, optimization and prototyping of power transformers

– Design of electromagnetic/mechanic energy

Course on design, optimization and prototyping of power transformers

Course on Design, Optimization and

Design model and design process

– Finite element method (multiphysics 2D, 3D)

Course on design, optimization and prototyping of power transformers

Equivalent circuit relations

Potential U=E·l N·I=H·l ϑ=G·l

Flow I=J·A Φ=B·A Q=q·A

Ohm’s Law U=I·R N·I=Φ·R ϑ=Q·R

Course on design, optimization and prototyping of power transformers

Thermal circuit (B)

T(k, :) = element k nodei node j Gij Gϑ = Q

2 1 3 G13 − G12 G12 + G23 − G23 0 ϑ Q