Blog #24 - The Real Transformer

This is a continuation of my series on Electromagnetism. In this blog I will be looking at The Real Transformer. You can find this topic in my course entitled…“Electrical 3 Phase Power Transformers Fundamentals”. You can access this, and my other courses in my Stan store, at this web address…https://stan.store/GVB

The ability of iron or steel to carry magnetic flux is much greater than it is in air, and this ability to allow magnetic flux to flow is called permeability. Most transformer cores are constructed from low carbon steels which can have permeability's in the order of 1500 compared with just 1.0 for air. This means that a steel core can carry a magnetic flux 1500 times better than that of air. However, when a magnetic flux flows in a transformers steel core, two types of losses occur in the steel. One termed “eddy current losses” and the other termed “hysteresis losses”.

In REAL TRANSFORMERS several non-ideal factors occur three of the major ones are:

Copper losses (I2R)

Leakage Flux losses

Core Excitation and

Core losses 1) Eddy currents 2) Hysteresis losses

Transformer Eddy Current Losses are caused by the flow of circulating currents induced into the steel caused by the changing magnetic flux around the core. These circulating currents are generated because the changing magnetic flux sees the core as a single loop of wire. Since the iron core is a good conductor, the eddy currents induced by a solid iron core will be large. Eddy currents do not contribute anything towards the usefulness of the transformer, but instead they oppose the flow of the induced current by acting like a negative force generating resistive heating and power loss within the core.

Eddy current losses within a transformer core can not be eliminated completely, but they can be greatly reduced and controlled by reducing the thickness of the steel core. Instead of having one big solid iron core as the magnetic core material of the transformer or coil, the magnetic path is split up into many thin pressed steel shapes called “laminations”.

These laminations are insulated from each other by a coat of varnish to increase the effective resistivity of the core thereby increasing the overall resistance to limit the flow of the eddy currents. The result of all this insulation is that the unwanted induced eddy current power-loss in the core is greatly reduced, and it is for this reason why the magnetic iron circuit of every transformer and other electro-magnetic machines are all laminated. Using laminations in a transformer construction reduces eddy current losses.

Transformer Hysteresis Losses are caused because of the friction of the molecules against the flow of the magnetic lines of force required to magnetise the core, which are constantly changing in value and direction first in one direction and then the other due to the influence of the sinusoidal supply voltage. This molecular friction causes heat to be developed which represents an energy loss to the transformer. Excessive heat loss can overtime shorten the life of the insulating materials used in the manufacture of the windings and structures.

Also, transformers are designed to operate at a particular supply frequency. Lowering the frequency of the supply will result in increased hysteresis and higher temperature in the iron core. So reducing the supply frequency from 60 Hertz to 50 Hertz will raise the amount of hysteresis present, decreased the VA capacity of the transformer.

But there is also another type of energy loss associated with transformers called “copper losses”. Transformer Copper Losses are mainly due to the electrical resistance of the primary and secondary windings. Most transformer coils are made from copper wire which has resistance. This resistance opposes the magnetising currents flowing through them. Not only that, when a load is connected to the transformers secondary winding, large electrical currents flow in both the primary and the secondary windings, electrical energy and power (or the I2 R) losses occur as heat. Generally copper losses vary with the load current, being almost zero at no-load, and at a maximum at full-load when current flow is at maximum.

A transformer’s rating can be increased by better design and transformer construction to reduce these copper losses. Transformers with high voltage and current ratings require conductors of large cross-section to help minimise their copper losses. Increasing the rate of heat dissipation (better cooling) by forced air or oil, or by improving the transformers insulation so that it will withstand higher temperatures can also increase a transformers rating.

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