Square Cruciform 3 stepped 4 stepped 5 stepped 6 stepped
0.45 0.56 0.6 0.62 0.64 0.65
Transformer Design
a=0.7071 d a = 0.85 d a = 0.9 d a = 0.93 d a = 0.95 d a = 0.96 d
b = 0.526 d b = 0.707 d b = 0.8 d b = 0.846 d b = 0.88 d
c = 0.42 d c = 0.6 d c = 0.707 d c = 0.77 d
d = 0.36 d d = 0.53 d d = 0.64 d
Core Limb
e = 0.314 d e = 0.48 d
f=0.28 d
Cross Section
Anand Jain, Hod EE
Government Polytechnic Hanumangarh
Square Cruciform 3 stepped 4 stepped 5 stepped 6 stepped
Transformer
0.45 0.56 0.6 0.62 0.64 0.65
a=0.7071 d a = 0.85 d a = 0.9 d a = 0.93 d a = 0.95 d a = 0.96 d
b = 0.526 d b = 0.707 d b = 0.8 d b = 0.846 d b = 0.88 d
c = 0.42 d c = 0.6 d c = 0.707 d c = 0.77 d
d = 0.36 d d = 0.53 d d = 0.64 d
Design
e = 0.314 d e = 0.48 d
f=0.28 d
Core Limb
Cross Section
In a transformer time varying alternating excitation in primary winding
turns generate working alternating flux in the core limb. The magnitude
of flux will decide number of turns in the winding.
The magnitude of flux depends on value of flux density in core and net
iron cross section area of core.
The value of flux density called specific magnetic loading depends on
core material and type of cooling used in transformer. If specific
magnetic loading is decided and fixed then the net iron cross section
area of core is most fundamental and important design parameter in
transformer.
Let us understand how it is related to different specifications of
transformer.
The output VA rating of transformer in KVA per phase is given as
V=rated voltage, I=full load current, IT=full load amp.turm or MMF Et= emf per turn
Here emf per turn
f =frequency of supply, Bm=maximum flux density in core, Ai=net cross section area of core
To increase output of transformer we can increase either Et or IT or both.
If only Et is increased, we have to increase Ai or core volume or investment in iron part.
If only IT is increased, we have to increase copper volume or investment in conductor part.
If we achieve a best design ratio of Et and IT for one particular power output of transformer to give optimize
result, then the same ratio will give similar optimized result for all other output ratings of similar type of
transformer.
Hence
Per phase KVA
Analysis and design of all type’s transformer is based on electromotive force – EMF equations.
When apparent power of the transformer is given, the EMF per turn E t can be calculated from:
S – Apparent power of the transformer in kVA n – Number of phases of the transformer
K – Factor which value will depend upon the following:
a) Type of the transformer ( core or shell type)
b) Service conditions (distribution or power transformer)
c) Labor charges and material conductor and core prices
d) Factory organization and design optimization parameter
Value of factor K for:
√
three phase core-type power transformer K = 0.6 to 0.65
𝑺
three phase core-type distribution transformer K = 0.45 to 0.5
𝑬 𝒕= 𝑲
three phase shell-type transformer K = 1.2 to 1.3 𝒏
single phase core-type transformer K = 0.75 to 0.8
single phase shell-type transformer K = 1.0 to 1.1
Once Et is known, the net cross-sectional area of the core can be determined from:
Bm – maximum flux density in the core of the transformer in Wb/ m 2
f – Frequency of the power supply in Hz
With very small size transformers, rectangular core can be used with either circular or rectangular coils. With
small size transformers, square core is used, with circular coils. With medium and large transformers, cruciform
(two stepped) or more stepped cores are used. Stepped core utilize the iron space better.
Circular coils are preferred over rectangular coils because of their superior
mechanical characteristics. On circular coils the forces are radial and there is
no tendency for the coil to change its shape. On rectangular coils the forces
are perpendicular to the conductors and tend to give the coil a circular form,
thus deforming it. Hence circular coils are employed in all transformers.
In square cores the diameter of the circumscribing circle is larger than the diameter of stepped cores of same area of
cross-section. Thus when stepped cores are used the length of mean turn of winding is reduced with consequent
reduction in both cost of copper and copper loss.
However with larger number of steps a large number of different sizes of laminations have to be used. This results in
higher labor charges for shearing and assembling different types of laminations.
For large transformers stepped core is used. The number of steps is increased according to the increase in the kVA
rating of the transformer, or the diameter of the limb of the transformer.
The relation between circumscribe circle diameter “d” and core cross section “Ai” can be expressed as follows
𝟐
𝑨 𝒊 =𝒌 𝒅
Ai – core cross-section of the transformer,
d – diameter of circumscribe insulating tube,
k – depends upon the number of steps of core of the transformer.
The value of constant k is as
Square Cruciform 3 stepped 4 stepped
√
5 stepped
45
0.62
=¿ 8.52
6 stepped
0.45 0.56 0.6 0.62 0.64 0.65
By increasing the number of steps, the area of circumscribing circle is more effectively utilized. The most economical
dimensions of various steps for a multi-stepped core can be calculated. The results are tabulated in table below:
Square Cruciform 3 stepped 4 stepped 5 stepped 6 stepped
0.45 0.56 0.6 0.62 0.64 0.65
a=0.7071 d a = 0.85 d a = 0.9 d a = 0.93 d a = 0.95 d a = 0.96 d
b = 0.526 d b = 0.707 d b = 0.8 d b = 0.846 d b = 0.88 d
c = 0.42 d c = 0.6 d c = 0.707 d c = 0.77 d
d = 0.36 d d = 0.53 d d = 0.64 d
e = 0.314 d e = 0.48 d
f=0.28 d
In actual practice we use 5 to 12
stepped core in transformer limb
construction. But for examination
point we can use data of 3 step or 4
stepped core in our design answers.
It is worth mentioning that a new type of electrical steel known as
"Amorphous" have appeared relatively recently which offer considerable
reduction in losses compared to conventional electrical steel. The use of
Amorphous steel is still limited due to the available size of strips which are
only suitable to build small distribution transformers with a rating less than
160 kVA. Another reason of limitation in usage is the poor stacking factor
(less than 0.9) due to the thinner used sheets.
