A CAD Integrated System for Epoxy Resin Casting Dry Type Transformers

Tao Li, Ping Sun, Qingquan Qiu, Bin Wang, Qingfu Li

School of Electrical Engineering, Xi'an Jiaotong University, Xi'an, 710049, China

Abstract-A CAD integrated system for epoxy resin casting dry type transforners is described in the paper. Electromagnetism calculation module, parameterized automatic generating drawing paper module and engineering database module are combined in the CAD integrated system. The Electromagnetism calculation module includes optimum design for core sectional area, synthesis design, analogy design, and optimum design for complete transformer. The CAD system is supported by engineering database, which combines design parameters, design criterion, designed schemes, and so on. Not only the new schemes can be designed, but also the designed schemes can be regulated artificially by analogy design module and further improved by optimum design module which is based on GA algorithm. Because the technique of the die arrangement of the transformers is intricate and the cost of it is high, the transformer can be designed automatically with the die arrangement existed. Applying the CAD system, the transformer can be designed automatically, the material cost is reduced, and the design cycle is shortened.

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Index Terms-epoxy resin; dry type transformer; CAD; engineering database

I. INTRODUCTION

SYSTEM STRUCTURE

In recent ten years, the demand of domestic market for dry type transformers has been dramatically increased, and the competition among manufacturers becomes more and more drastic. Consequently, it is significant for manufacturers and designers to shorten the design cycle, enhance the design efficiency, and reduce the material cost. With the rapid development of computer technique, CAD is widely used in transformer design[ 1][2]. But the traditional CAD systems only include some aspects of transformer design, such as normal design, optimum design, generating drawing paper, all of which are not integrated. Furthermore, the data of these CAD systems can hardly be used by other software directly, so the data are hard to be shared and the efficiency of the CAD system falls a lot. Database technology can achieve to share data, ensure the integrality and consistency of data. With engineering database, it is able to integrate all parts of the design procedure. Generally speaking, the engineering database is the core in the developed CAD integrated system for epoxy resin casting dry type transformers, and it connects every part of the system, transfers and shares data. It integrates the production design, data store, and computer drawing. Moreover, the optimum design is adopted to reduce the material cost.
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As shown in Fig. 1, the whole system includes engineering database, engineering database management subsystem, production design subsystem and parameterized automatic generating drawing paper subsystem. Among these, engineering database is the core, whose function is to store the engineering data during the transformer design and the schemes designed. Management subsystem is to manage, update, and maintain the engineering database. Production design subsystem is to design the proper scheme and analyze the scheme performance based on technical demand. On the one hand, after production design, according to electromagnetism design scheme and structure design principle, the parameterized automatic generating drawing paper subsystem is to generate drawing, on the other hand, the drawing paper of some schemes stored in the database can be generated directly without calculating. The drawing includes parts drawing and general assembly drawing. Fig. 1 illustrates that the database connects all the subsystems, and the degree of coupling is low. Using the database, the system is compact and the design is easy to
achieve.
III.

ENGINEERING DATABASE

Database is the core of the CAD system Transformer database belongs to engineering database and is upheld by Access database. There are two main kinds of data in transformer design, one is dynamic data which needs to be identified through many modifications, such as electromagnetism design data and structure design data, the other is static data, which is more stable and less changeable, such as design criterion, material data, some fixed parameters of the design, and so on. Usually the system is used to store the static data. Fig.2 shows the structure of the CAD system database. Lead database usually includes flat wire and round wire. Furthermore, with the change of thickness of flat wire or diameter of round wire, the insulation thickness of wire is also changed. In order to manipulate and calculate easily, the database of the insulation thickness of wire is also built. For high-capacity transformer, low voltage coil usually adopts copper foils or aluminum foils. Although different types of foils can be spoken for at will, the stocks are large in many manufacturers. As a result, foils can be chosen by the system automatically. If the chosen foil is not suitable for the design, new foils can be used, which can improve the utilization ratio of material. Silicon sheet database stores some usual types of silicon sheet. To compute effectively, core parameters database stores all kinds of parameters including core diameter, real sectional area, core section classifications, section width and thickness of all grades. Pouring die arrangement limits the structure dimension of transformer, manufacturers can make die arrangement based on design scheme. In fact, because the technique of the die arrangement of transformers is intricate and the cost of it is high, transformers can also be designed automatically with the die arrangement existed in this system. Otherwise the scheme is not optimal or new technical requirement or new structure is needed, the scheme can also be designed without the die arrangement existed, which makes the system flexible. In order to reduce workload and input error, a database on some parameters that remain stable or change gradually with the change of transformer capacity is built. With the help of that, it is not necessary for users to input all parameters instead of a few modifications.

Fig. 3. The structure of the design

A variety of national standards and enterprise standards for a series of dry type transformer are stored in production criterion database. The schemes which have been designed or temporary schemes are stored in temporary production database. After the scheme proves to be feasible and accords with experimental results, the scheme can be stored into finished production database. Database management subsystem can update, add, delete, change and query data of the engineering database. Considered the importance of database to product design, the CAD system encrypt data and junior designers can only visit data and senior designers have access to manage database.

IV. ELECTROMAGNETISM CALCULATE AND CONSTRUCION DESIGN SYSTEM

Fig.3 is the structure diagram of production design subsystem. In core sectional area optimum calculation module, the GA algorithm is adopted and the max sectional area is calculated based on diameter and section classifications. There are two kinds of coils for the low voltage coil of epoxy resin casting dry type transformers, wire coil and foil coil respectively. While calculating core sectional area, the necessary distance between core and low voltage coil must be kept. As a consequence, some sheets must be taken off. The gripping-plates of core with milling angle not only reduce the possibility of partial discharge but also benefit to add core sectional area. Considered the various manufacturing level of different manufacturers, the core sectional area based on the four types above can be calculated and the results can be stored into database directly. Since the CAD system is based on engineering database, the system can achieve automatically choosing core parameters, emplacing windings, choosing wire and adjusting short-circuit impedance, if necessary, choosing foil and pouring die arrangement. All of these lead to electromagnetism calculation. It is very simple for transformer designers to generate a scheme according to technical specifications based on high voltage, capacity, and insulation requirement.

Fig. 2. The structure of the engineering database

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Adopting database technology for synthesis design, when fixing capacity and high voltage, users only need to identify the initial value of magnetic flux density, current density of low voltage winding, and current density of high voltage winding. Other parameters can be read from database and users can modify them on the
Title

interface. Analogy design is to ameliorate the existing scheme in the database in order to achieve design goal. During the design, users only input the type of transformer, then pick up the existing scheme and the parameters of design appear on the interface.

TABLE I SCHEMES COMPARISON SCB9-630/10

Number of turns of low voltage coil Core diameter (mm) Core sectional area (mm') Width of foil (mm) Current density of low voltage coil (A/mm2) Current density of high voltage coil (A/mm2) Unload loss (KW) Load loss (KW) Unload current (A) Short-circuit impedance
Temperature rise of core Temperature rise of low voltage coil ( C) Temperature rise of high voltage coil ( C) Material cost ( Y ) Fall ratio of material cost

Initial Scheme 21
217 330.3 810 0.936
1.846 1390 5880 0.48 5.91 75.76 81.36 85.21 47476

Optimum Scheme I 20
221 341.55 720 1.148

Optimum Scheme II
20 217 336.25 715 0.978 2.089 1439 6178 0.57 6.15 79.12 90.65 99.59 43379 8.63%

Initial Scheme 15
262 490.4 1100 0.965 1.7 2130 10088 0.33 5.95 70.55 73.56 77.39 84533

SCB9- 1 250/10 Optimurm Scheme I 15

258 473.5 1095 0.915 1.806 2250 10252 0.37 6.00 72.68 73.70 79.46 81281 3.85%

Optimum Scheme II 13
276 550.65 840 1.193 1.831 2318 10244 0.38 5.99 76.77 87.52 92.91 78770 6.82%

1.854 1425 6065 0.53 5.96 82.66 90.79 95.15 45436 4.3%

(0%)

( C)

(0%)

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The principle of optimum design for transformers is to achieve the lowest cost at the precondition to meet with the design demands. The GA algorithm is adopted as the optimum algorithm in the CAD system which is very effective. Core diameter, the number of turns of low voltage coil, the height of low voltage coil, current density of low voltage coil, current density of high voltage coil are chosen as optimum parameters and unload loss, unload current, load loss, short-circuit impedance, temperature rise of core, temperature rise of low voltage coil and temperature rise of high voltage coil are chosen as constraint conditions. After the optimum design, the main performance index of five schemes will be shown on the interface, users can choose the best scheme based on actual situation and the scheme is stored into the database.
V. AUTOMATIC DRAWING SYSTEM

optimum scheme II shows the results under the conditions of the gripping-plates with milling angle. It is clear that the optimum arithmetic which the system adopts is effective and the gripping-plates with milling angle can improve design level and reduce the material cost. But, high technology is required for manufacturers to adopt the gripping-plates with milling angle and manufacturers can choose it at will.
VII. CONCLUSION

The automatic drawing system chooses parameterized automatic drawing software as the development plat. After design, the CAD system connects drawing software automatically, stores the data calculated by electromagnetism design and structure data into the database and the drawing software can generate blueprint automatically, including parts drawing, general assembly drawing and list. Fig.4 shows the general assembly drawing.
VI. EXAMPLE OF CALCULATION

The CAD integrated system for epoxy resin casting dry type transformers is presented in the paper. The database for transformer design and management subsystem for data maintenance are set up, and core sectional area optimum calculation module, synthesis design module, analogy design module and optimum design module based on this database are developed. Through the connection with parameterized automatic drawing software, the automatic design of transformers is achieved, the cycle of design is shortened, and the efficiency of design is enhanced. And it has great actual value in project design.
REFERENCES
[2] Qihe Li, Erkui Chen, Wei Hao, "Development of system of CAD for dry type power transformer", Journal of Gansu University of Technology Vol.27, No.2,pp. 13-16, Jun. 2001 [3] Changbai Lu, " Theory and calculation for dry type transformef', Liaoning: Liaoning Science and Technology Publishing House, 2003 [4] Yucheng Xie, "Handbook of Power Transformer", Beijing: China Machine Press, 2003 [5] Qingquan Qiu, Qingfu Li, Tao Li, "Research on Optimization Design for Cross Section of Transformer Core Based on Improved Genetic Algorithm", Transformer, Vol.41, No.9, pp:33-35, Sep.2004. [6] Shuwei Fan, Guoliang Wang, Wei Xie, "Genetic Algorithm and Its Application in Power Transformer Optimization Design", Proceeding o-fthe CSEE, Vol.16, No.5, pp:346-348, Sep.1996.

[1] Ming Cheng, E Zhou, Minqiang Hu, "Optimum design for dry type transformers and CAD system", Transformer, pp.2-4, Aug,1994.

between normal design and optimum design. The optimum scheme I shows the results under the condition of the gripping-plates without milling angle and the

Two kinds of epoxy resin casting dry type transformers are designed as examples of calculation, SCB9-630/10, with capacity of 630KVa and high voltage of 1OKV and SCB9-1250/10, with capacity of 1250KVa and high voltage of 1OKV. Table I exhibits the comparison

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