…

MINOR
PROJECT
Diploma Electrical Engineering 2nd
Year
 1.INTRODUCTION
A transformer is an electrical machine that works on
the principles of electromagnetic energy conversion.
It is a kind of device that transfers electrical energy
through the magnetic field from one electrical circuit
to another keeping the supply frequency constant.
The energy received from the supply mains is
denoted as the primary side and the energy-
distributing circuit to the load is denoted as the
secondary side. Transformers cannot create any
energy but rather transfer’s energy by changing
both the voltage and current levels of the circuit.
Transformers are commonly employed in electrical
power generation and distribution sites for
efficient transmission of electrical power to the
grid network and then subsequent distribution to
the end users.
The designed transformer can be used for laboratory demonstration with low loss and low
cost so that after implementation, the loss is minimized and efficiency is maximized for any
practical use. In this paper, we have explored to design of a low-loss small single-phase
step-down transformer having a capacity of 1 kVA with a turns ratio of 2.
1.1 Need of
Transformer
In most of the cases, appliances are manufactured to work
under some explicit voltage. Transformer is used to adjust
the voltages to a proper level. The transformer is the basic
components for the transmission of the electricity.
Transformer is use to increase the voltage at the power
generating station (step up) and to decrease the voltage
(step down) for house hold persistence. By increasing the
voltages the loss of the electricity in the transmission
purpose in minimalize
1.2 Hardware
requirement
• Bobbin
• Winding Machine
• Copper wire
• Stamping( E & I Shape)
• Transformer Clamp
• Resistor (4.7KΩ)
• Op Amp (LM 358)
• Transistor (BC 548)
• 9V DC Battery
• 5V DC Fan
• NTS Thermistor (4.7kΩ)
• Potentiometer (4.7kΩ)
 1.3 THE TRANSFORMER
DESIGN PROBLEM
In a design, a concept is given shape with the application of science, technology and invention to
realizationA.Design
of a machine so asConsiderations and
to content required performance and characteristics. A design
limitations:
process is not merely engineering calculations but involves careful considerations of the design
base, conditions, design transfer and information updating.
Knowing the characteristics and specifications that a transformer has to satisfy, the main areas of
design include:
• Magnetic circuit; core, window etc.
• The electric circuit; the windings.
• The insulation.
• The mechanical construction.
The designer’s work lies in properly allocating the space to frame, core, air gap, windings,
insulation and cooling circuit in the transformer. Moreover economy in manufacturing costs,
operating and running costs are also kept in vision.
Limitations are imposed on design because of:-
• Saturation of magnetic parts.
• Temperature rise under high output.
• Insulation breakdown due to high voltage gradients.
B. Selection Of Design Constants:
The design depends upon power choice of design constants, flux density (Bm), current density
(δ) and window space factor (KW). Therefore, it is worthwhile to discuss the factors governing
the choice of these coefficients.
If we choose higher value of flux density (Bm), the core area Ai reduces. This will reduce the
diameter of circum-circle thereby reducing the length of mean turn.
Thus there is saving in the cost of iron and copper. But very high flux density is not possible, the
restriction is because of iron losses, saturation and magnetizing current. Transformer should be
designed for lower iron losses giving good efficiency. Therefore, for small transformer
comparatively lower flux density (1.1 to 1.4 Wb/m2) is implicit.
The choice of current density (δ) affects the I2R losses and also the load at which maximum
efficiency occurs. The allowable values of current density for small power transformers are taken
as (δ =1.5 to 2.6 A/mm2).
The window space factor, Kw has been defined as the ratio of copper area in the window to the
total window area .The total window area includes the copper area, insulation and the air gap of
coil spaces. The relative amounts of copper and insulation used will influence the value of Kw.
The amount of copper and insulation used depends upon the KVA capacity and voltage rating
respectively. Thus choice of Kw depends upon KVA capacity and voltage rating. The following
experimental relation is normally used for estimation of Kw.
C. MATERIALS AND METHODS
In this work, a core-type single-phase transformer was intended to be
designed as shown in Fig. 1.

Fig. 1. A 3-D view and 2-D view of the transformer’s core design in AutoCAD
Fig. 2. A 2-D view of the designed transformer with primary and secondary
windings’ terminals in AutoCAD
Fig. 3. A 2-D side view of the designed transformer in
AutoCAD showing the E-shaped and Ishaped cores

Fig. 4. A 2-D top view of our transformer in AutoCAD shows the core on the base
D. SIMULATION AND EXPERIMENTAL
RESULTS AND DISCUSSION
To simulate the single-phase transformer, MATLAB Simulink was used. At first, the circuit was
drawn according to the design requirements. The ammeter and the voltmeter were
connected in series and parallel, respectively. A load resistance (R) was also connected to the
secondary side so that the secondary side draws current as shown in Fig. 6. Oscilloscope is
connected to both the primary and secondary sides to observe the primary and secondary
voltage and current levels. There are options for the rms current and voltage measurements,
also.