Transformer Modelling

This section covers the modelling of the 3 phase 100kVA Dry type energy efficient switchable transformer designed, by using the finite element modelling technique. The purpose of the modelling was to find out how the magnetic flux density distribution, magnetic field intensity distribution, thermal distribution on the industrial distribution transformer. In addition, the transformer modelling with finite element method also allowed for the eddy current present, impedance, and also power losses to be seen. This will allow for the purposes of optimizing and increasing the performance of the power transformer for the future design. Before start modelling the transformer, first thing is to research the industrial conventional transformer on its core size, window size as well as the volts per turn, for this project, proj2007z team members have visited ETSA to obtain all relevant 100kVA transformer information. After that, the transformer core is designed by according to the AEM core manufacturer standard. For the dry type transformer, the current density has to be maintained between 2.4A/mm2, and all the design parameter is depending on this factor. The purposes of developing the switchable transformer is to reducing the copper losses produced during high load, and core losses produced during low load period by switching the transformer to the parallel and series configuration respectively. Modelling a transformers characteristic by applying ANSYS finite element analysis, analysed the flux present in the transformer core material. This will model the effect of the core flux that has on the transformer. This modelling can be used to explore the effect has on the transformer core once the changed applied to the coil configurations. Beside that, the effect on the transformer performances and also the efficiency has on the transformer can also be shown under the modelling of the finite element method. This modelling provided a better way to investigate and hence more accurately

provided information of the transformer before the actual design of the transformer.

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Finite Element Modelling (FEM)

The finite element modelling software used for modelled this 3 dimensional 100kVA distribution transformer is the ANSYS Multiphysics ver.10 software elaborated with the PRO Engineering Wildfire 3.0 CAD software. The ANSYS software is a powerful tool for the 2D and 3D finite element simulation software with the ability to animate the results. Pro E CAD software is a powerful tool to design in 3 Dimensional prospective hence it is user friendly and it had in house experts that able to recommend the most suitable software for the 3 Dimensional design.

Figure 1: 3 phases Dry type Transformer [http://www.emeraldinsight.com/fig/1740200226017.png]

Construction of the 3 Dimensional Models

The first step of the finite element modelling is to construct a 3 dimensional model with using the ProEngineering CAD software. From the reference of the AEM core manufacturer data, the core selected is one size bigger than the conventional 100kVA transformer. The core chosen was E600/110/120/190 where it indicated the high, depth, leg width and also the window width respectively in millimetres. The figure below depicted the geometry model of a 100kVA power drawn by the ProEngineering CAD software.

Figure 2: Geometry model of 100kVA Transformer in ProE Secondly, this geometry model was imported into ANSYS Multiphysics work space and the figure below indicated the 100kVA geometry models in ANSYS work space. The difference in colour indicated the phase A, B and C primary and secondary winding and also the core material for the 100kVA energy efficient transformer.

Figure 3: 100kVA transformer in ANSYS Environment

Step in the ANSYS Multiphysics Finite Element Analysis

Establishing Model
In defining the physics environment for an analysis, you establish a mathematical simulation model for the physical problem. In the ANSYS electromagnetic analysis, the electromagnetic fields are governed by Maxwells Equations such as { H } = { J } +
D D = {Js} +{Je} +{Jv} + , t t

B { E} = , { B} = 0 and also { D} = where t

{H } = magnetic field intensity vector

{ J } = total current density vector

{ J s } = applied source current density vector { J e } = induced eddy current density vector { J v } = velocity current density vector
{D} = electric flux density vector
{B} = magnetic flux density vector = electric charge density

Mesh Generation and Parameter Setting

In order to perform the finite element analysis of the 100kVA dry type distribution transformer, the next thing is to perform transformer model meshing. The ANSYS Multiphysics software provides with the ability to mesh the model with triangle elements. The size of these triangle elements determined how fine or how coarse the finite element modelling of the model will be in the mesh calculation of the software. The triangles spacing can be set as desired value depending on the setting during the meshing process of the model. In the 3 dimensional analyses, the meshing is normally started with the coarser so that to ensure that the computer used to perform the analysis can cope with the memory taken during the operation. The area required greatest or frequent change required finer triangle mesh size. For the case of the transformer, the transformer core required much finer mesh size compared to other element in order to verify the regions of the transformer core with rapid changed that occur.

Figure 4: Build and Mesh of the100kVA Geometry model of transformer

For the model created, materials properties need to be assigned to each component. Below showed the B-H table and material properties of the M3 high efficiency silicon steel for the electromagnetic material of the transformer core. These values are inserted via the material library from the ANSYS software.

Figure 5: B-H properties of M3 High Efficiency Silicon Steel

Applied Boundary Condition and Load

This modelling for the 100kVA transformer model in three phases 3 dimensional, the primary coil has the width of 60.0559mm whereas the secondary coil has the width of 19mm with in between the both winding, it has a insulator of about 3mm thickness. The core has dimension of 600mm window height, 190mm for the window width, 110mm for the leg width and with depth of 120mm as shown on the geometry model shown on figure 1. The primary coil has total 2097turns numbers of winding, and secondary has the total winding of 115turns. This transformer is modelled by stranded coil with SOURC36 and a solid conductor using solenoid (F,,amps) loading. This demonstration was intended the main flux of the coil in three phases transformer.

Figure 6: Applied load and energy distribution model The green colour indicated the applied voltage; the purple colour indicated the current distribution on the coil of the transformer.

Conclusion
The development of the model was not an easy and beside that it is very time consuming to produce a model. The model was required to duplicate the physical transformer itself to be as accurate as possible to the actual condition itself. In order to achieve or modelled an actual transformer, it required a brilliant idea and intricate knowledge regarding the quality of the core and also how does it effects the performance of the model as the difference DOF was selected. ANSYS Multiphysics is a software that required a lot of practices and also it is very powerful on the three dimensional analysis of the finite element model. But due to the time constraint, the overall transformer modelling is unable to complete on the time given. Therefore this project might be carried on by the new project students to accomplish for next year. Generally, in actual transformer the flux leakage into the surrounding air would be substantially higher for the central leg thus it can reduced the flux density on the other two of the outer core legs. This finite element modelling is worth learning for further use for work, but again the finite element modelling on three dimensional performance of the transformer required great deal on knowledge and also required a lot practicing on the software use.