Objective
To design and construct a 200 KVA energy efficient 3-phase, 3 limb transformer cores, and to incorporate new features in its design which will prove beneficial in energy saving.
Work has been completed on the assessment of the various methods of assembling magnetic cores in order to choose a transformer design which will make the best use of core material magnetic properties (most present commercial designs cause a high building factor which creates extra core losses in a transformer and hence does not make the best use of the ecellent basic magnetic properties of core materials).
During this period the final design of a novel 200 KVA core has been finalised.
Investigations and discussions with designers at the South Wales Transformers Ltd led to the conclusion that a notched yoke, 3-limb transformer of 200 KVA rating should be assembled at the Wolfsen Centre, prior to final coil winding etc. at the transformer plant. Before final assembly the optimum stagger length should be confirmed by preliminary measurement of losses and magnetising current in the transformer/using temporary windings.
Laminations were staggered layer by layer in one core in order todemonstrate the benefit of the technique on core efficiency : optimum conditions were obtained with a stagger length of 1.0 cm with 15 cm/laminations./wide. Core loss was reduced by 5-10%. Other laminations were cut at angles to the rolling direction and re-assembled in order to demonstrate benefits which may be obtained using this technique.
The transformer design for the demonstration had a core weight of 315 Kg. The guaranteed loss of the manufacturer's conventionally designed equivalent transformer was 330 W. The new design produced a loss of 230 W (a capitalised loss saving of around 300 UKL for the 200 KVA transformer).
Core laminations have been cut from laser scribed high permeability grain oriented silicon iron. The laminations were cut from a mother coil 0.23 mm thick, from which strips for Epstein and single strip testing were also cut. The power loss and magnetic induction of the Epstein strips over a range of flux densities from 1.7T to 1.8T have been measured.
With all basic magnetic measurements on core starte steel completed, final testing of the 200 KVA core at the end of March 1986. Testing of various packets of the core separately with different stagger lengths was performed before sending the assembly to South Wales Transformers for the completion of assembly and acceptance testing.
The completed transformer was tested and installed on site of a user. The transformer has been operating satisfactorily at its low rating.
This is a 3 phase project for the design and construction of an energy efficient 200 KVA transformer. In phase 1, cut-laminations were purchased for assembly in new core configurations. The work in this phase focused on assembly design. Two improvements are proposed:
(1) staggering layers of laminations in a core, and,
(2) cutting laminations at small angles to the rolling direction of the sheet before assembly.
During phase 2, the proposed improvements in the new core will be evaluated. Arrays of thermistors are installed on the laminations in order to monitor the variation of localised loss with stagger length. Variations in the grade of steel used in the yoke and limb laminations will also be tested. Once a final design is developed based on phase 2 test results, phase 3 - the installation of the newly designed core in a working transformer site - will commence. The project is now in the final stage of phase 2.
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Coordinator
CF2 3AD CARDIFF
United Kingdom
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