ELET-2141

Introduction to Power Systems

Design of a Transformer

Submitted to: Dr. Maciej A. Noras

Submitted by: Grayson Berreth
Date Submitted: 11/9/2016

Introduction

The purpose of this experiment was to design a transformer using specific parameters that were
assigned by the professor. The transformer will be designed by choosing the specific lamination,
and the type of wire each coil will use. The transformer must met two requirements one being
that the transformer must have a window utilization, Ku, less than 0.4. The transformer must also
have a temperature rise of less than 40C.
Procedure
Step 1 Calculate the transformer apparent power,
Pt =180

( 0.921 +1)

Pt

, [watts]

Pt =375.65 , [watts]
Step 2 Calculate the electrical conditions,
2

Ke

K e =0.145(4.44 )(60 )(1.6 )(10 )

K e =2.63
Step 3 Calculate the core geometry,
Kg=

Kg

375.65
c m5 ]
2( 2.63)(6) , [

K g =11.90 , [ c m5 ]
Step 4 Select a lamination comparable in core geometry,
Lamination number: DU-75
Manufacturer: DU lamination
Magnetic path length, MPL: 34.3 cm
Core weight, W tfe : 985.2 grams
Copper weight, W tcu : 1467.0 grams
Mean length turn, MLT: 14.2 cm
Iron area, Ac: 3.448 cm2
Window area, Wa: 29.032 cm2
Area product, Ap: 100.091 cm4
Core geometry, Kg: 9.7136 cm5
Surface area, A: 537.1 cm2

Kg

Step 5 Calculate the number of primary turns, Np

N p=

(120 ) ( 10 4 )
(4.44)(1.6)(60)(3.448) , [turns]

N p=817 , [turns]
Step 6 Calculate the current density, J
375.65(104 )
2
J=
( 4.44)(0.4)(1.6)(60)(100.091) , [amps/cm ]
J =220.127 , [amps/cm2]

Step 7 Calculate the input current, Iin

I=

180
120(0.92)

I =1.63 , [amps]
Step 8 Calculate the primary bare wire area, Awp(B)
A ( B) =

1.63
2
220.127 , [cm ]

A ( B)=0.0074 , [cm2]
Step 9 Select the wire
AWG = #18
A ( B)=0.00822 , [cm2]
A = 0.00933, [cm2]

( cm )=

209.5, [micro-ohm/cm]

Step 10 Calculate the primary resistance, Rp

6

R p=(14.2)(817)(209.2)(10 ) , [ohms]

R p=

2.43, [ohms]

Step 11 Calculate the primary copper loss, Pp

P p=(1.632)(2.43) , [watts]
P p= 6.46, [watts]
Step 12 Calculate the secondary turns, Ns
Ns=

( 816.5 ) ( 60 )
6
(1+
)
120
100 , [turns]

N s =433 , [turns]
Step 13 Calculate the secondary bare wire are, Aws(B)
A ws (B ) =

(3)
2
220.127 , [cm ]

A ws (B ) = 0.0136, [cm2]
Step 14 Select the wire
AWG = #16
A ( B)=0.013 , [cm2]
A = 0.0147, [cm2]

( cm )=

131.8, [micro-ohm/cm]

Step 15 Calculate the secondary winding resistance, Rs

6

Rs =(14.2)(433)(131.8)(10 ) , [ohms]
Rs = 0.81, [ohms]
Step 16 Calculate the secondary copper loss, Ps
Ps=(32 )(0.81) , [watts]

Ps= 7.29, [watts]

Step 17 Calculate the total primary and secondary copper loss, Pcu
Pcu=7.29+ 6.46 , [watts]
Pcu= 13.75, [watts]
Step 18 Calculate the transformer regulation,
=

13.75
180 , [%]

= 0.076, [%]
Step 19 Calculate the watts per kilogram, W/K
W / K=0.000557(601.68 )(1.61.86 )
W / K=1.296
Step 20 Calculate the core loss, Pfe
Pfe =(1.296)(0.9852) , [watts]
Pfe =1.28 , [watts]
Step 21 Calculate the total loss, P
P =13.75+1.28 , [watts]
P = 15.03, [watts]
Step 22 Calculate the watts per unit area,
=

( 15.03 )
2
536.1 , [watts/cm ]

= 0.028, [watts/cm2]

Step 23 Calculate the temperature rise, Tr

T r =450(0.0280.826 ) , [C]

T r = 23.47, [C]
Step 24 Calculate the total window utilization, Ku
K us=

( 433)( 0.0136)
29.032

K us= 0.2028
K up=

(817)(0.008)
29.032

K up= 0.3658
K u=0.2028+ 0.2251
K u=0.4279
Results
Transformer specifications and obtained experimental values
VIN
VO
IO
F

BAC
CORE MATERIAL
KU
TR

SPECIFICATIONS
120 V
60 V
3A
60 Hz
92%
6%
1.6 T
Silicon M6X
<0.4
<40C

EXPERIMENTAL VALUES
7.6%
Silicon M6X
0.43
23.47C

Table 1.1
As shown above in table 1.1 the specified transformer regulation is 6% and the experimental
value is 7.6%. The two values have a 26% difference, this can be caused by the chosen wires
having a larger loss than in the specified transformer configuration.
The prescribed window utilization was 0.4, and the experimental value is 0.43. The experimental
value is slightly larger than the specified value, this could be due to how the turns of each coil
had to be rounded up. For example, the turns for the primary coil was originally 816.5 turns,
however it must be rounded up which may cause rounding errors when computing the window
utilization. The specified temperature rise was to be less than 40C, using the experimental

values the temperature rise was 23.47C. The experimental value falls within the specified
temperature.
Conclusion
In conclusion, the experimental transformer produced similar values to that of the specified
transformer. The difference in values can be caused by a multitude of things one of which being
the rounding errors caused by rounding the turns up to the next whole value. Another explanation
for the difference in values is that the lamination selected could be different than that of the
specified transformer. All in all, the experimental transformer could come close the specified
values and the difference in values can be accounted for by several reasons.

References
Transformer specifications and obtained experimental values
VIN
VO
IO
F

BAC
CORE MATERIAL
KU
TR

SPECIFICATIONS
120 V
60 V
3A
60 Hz
92%
6%
1.6 T
Silicon M6X
<0.4
<40C
Table 1.1

EXPERIMENTAL VALUES
7.6%
Silicon M6X
0.43
23.47C

Appendix