International Research Journal of Engineering and Technology (IRJET)
eISSN: 23950056
Volume: 05 Issue: 04  Apr2018
pISSN: 23950072
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Analysis and Design of Toroidal Transformer Harshit Sawant1, Keyur Patel2, Rahi Tapare3, Prof. Darshit Patel4 1, 2, 3 Students,
Department of Electrical Engineering, Vadodara institute of engineering, Kotambi, Vadodara390018, Gujarat, India 4Assistant professor, Department of Electrical Engineering, Vadodara institute of engineering, Kotambi, Vadodara390018, Gujarat, India ***
Abstract – A Toroidal transformer provides increased
design flexibility, efficiency & compact design when compare to traditional shell & core type transformers. The design of most efficient toroidal transformer that can be built gives the frequency, volt ampere ratings, magnetic flux density, window fill factor and material which can use. With the above all constant and only the dimension of the magnetic core is varied. The most efficient design occurs when the copper losses equal 60% of iron losses. When this criterion is followed efficiency is higher. The model parameter calculated from the design information. Therefore it is suitable to be included in design loop of transformer design software. The results are compared with the finite element simulations. Key Words: Toroidal core, Toroidal Transformer
1. INTRODUCTION This the purpose of this project is currently used in low voltage low power applications, is to use a core made up of continuous steel strip that is wound into a construction allows for smaller more efficient, lighter and cooler with reduced electromagnetic interferences lower acoustic noise. The main technical advantage is that the no load losses substantially reduced. It is possible to replace oil immersed transformer with dry toroidal units, reduce the potential for violent fault in addition to environmental benefits of avoiding the use of oil.
1.1 Design Principle symbols: V1 = Primary voltage V2 = Secondary voltage I1 = Primary current I2 = Secondary current P = Power Do = Outer diameter Di = Inner diameter A = Cross sectional area of core H = Height of core
Impact Factor value: 6.171
1.1.3 Calculation of primary side:42 A
= Tp×volt
Assumptions for design calculation: Assumption based on our input based and a fixed power value based we can directly finding on internet source and use that values according to some reference. 18cm = Do 8cm = Di 10cm= A 8cm = H Cross sectional area of core 10×8=80cm Equivalent core area = =
80 2
40m2
Numbers of turns: 42 Turns×volt = A 42 Tp = = 1.05 v [no. of turns/volt] 40 So now, Primary turns = Primary voltage/ Number of turns/volt Tp = 235/1.05 = 224 Tp Assume 40cm cross sectional area of winding Total wire = Cross sectional area × Numbers of turns in primary side 40cm × 224 Tp = 8960cm = 89.60M Wire use for primary winding P V1
1200 5.10 A 235 I= P = 1200 10 .43 A 115 V2
Ts = Number of secondary Turns

V1= 220, V2=120, P=1200, Do=18cm, Di=8cm, A=10cm, H=8cm
I=
Tp = Number of Primary turns
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1.1.2 Consideration input assumptions for design of toroidal transformer:

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International Research Journal of Engineering and Technology (IRJET)
eISSN: 23950056
Volume: 05 Issue: 04  Apr2018
pISSN: 23950072
www.irjet.net
Table select for gauge of winding wire:
1.2 SIMULATIONS: Analysis of toroidal transformer
Table 1.1: Gauge of winding wire Windings Gauge Circular Diameter mill in mm Secondary 13 5178 1.83 Secondary 14 4170 1.63 Primary 16 2583 1.29 Primary 17 2048 1.15
Ampere
1.2.1 Design of toroidal transformer:
10.5 8.3 5.2 4.1
Wire calculation in gram:= Diameter × gauge = 1.26 × 16 = 20.64 gram Fig. 1.2.1: Design of toroidal transformer
1 m weight of wire is 20.64 gram. 89.60 m weight of wire is 1849.344gram.
We are using such a parameter in FEMM above figure:
1.1.4 Calculation for secondary winding:
Material use for Core is M15 Steel.
Ts = Secondary voltage/ no. of turns per volt V2=120 = 115/1.05 = 110Ts Assume 42cm cross sectional area of winding Total wire = Cross sectional area × Numbers of turns in Secondary side = 42 × 115cm= 4830 = 48.30m For, 1m weight of wire is 23.69 gram. 48.30 m weight of wire is 1144.22gram.
Gauge of primary windings is 14AWG. Winding turns are 235 for primary side. Gauge of secondary windings is 16AWG. Winding turns are 110 for secondary. Insulating medium is Air.
1.2.2 Primary winding parameter :
1.1.5 Design data sheet: Table 3.2: Design data sheet Sr. No
Design parameter
Value
1.
Primary voltage
V1 = 235
2.
Secondary voltage
V2 = 115
3.
Primary current
I1 = 5.10
4.
Secondary current
I2 = 10.43
5.
Power
P = 1200watt
We are going towards the analysis of primary winding parameter for getting results:
6.
Number of primary turns
Tp = 224
Total current is 11amp.
7.
Numbers of secondary turns
Ts = 110
Voltage drop is 0.666378 volts.
8.
Outer diameter
Do = 18cm
Flux linkage is 0.710245 Webbers.
9.
Inner diameter
Di = 8cm
Flux/current is 0.645677 henries.
10.
Cross sectional area
A = 10cm
Voltage/current is 0.0605798 ohms.
11.
Height
H = 8cm
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Impact Factor value: 6.171
Fig. 1.2.3: Primary winding parameter
Power is 7.33016 watt.

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International Research Journal of Engineering and Technology (IRJET)
eISSN: 23950056
Volume: 05 Issue: 04  Apr2018
pISSN: 23950072
www.irjet.net
1.2.4 Secondary winding parameter:
1.2.6 Magnitude of flux density for secondary:
Fig. 1.2.6: Magnitude of flux density for secondary
Fig. 1.2.4: Secondary winding parameter We are going towards the analysis of secondary winding parameter for getting results: Total current is 6 amps. Voltage drop is 0.288971volts.
This graph represents the magnitude of flux density for secondary winding. This graph will be L→B. Here, L is representing length in terms of inches and B represent magnetic field in terms of tesla.
2. Hardware Implementations:
Flux linkage is 0.355159 Webbers.
2.1 Toroidal Transformer Core:
Flux/current is 0.0591932 henries. Voltage/current is 0.0481618 ohms. Power is 1.73383 watt.
1.2.5 Magnitude of field intensity for primary: This graph represents the magnitude of field intensity for primary winding. This graph will be L → H. L represents length in terms of inches and H represent flux density in terms of amp/m graph shape will be longitudinal. Fig. 2.1: Toroidal Transformer core In this above figure we can see that the core diameter, width & height. That was be like a design data sheet height is 8cm, inside diameter is 8cm, outer diameter is 18cm and the cross sectional area is 10cm. That was be clearly mention & seeing in above figure.
2.2 Toroidal Transformer:
Fig. 1.2.5: magnitude of field intensity for primary
Fig. 2.2: Toroidal Transformer © 2018, IRJET

Impact Factor value: 6.171

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International Research Journal of Engineering and Technology (IRJET)
eISSN: 23950056
Volume: 05 Issue: 04  Apr2018
pISSN: 23950072
www.irjet.net
Above figure in which we see that toroidal transformer hardware Completed with winding of the core. In which one side input terminal that side we given input as a 230volt and output we get 110volt. In the figure the black wire is a input terminal and the red wire is output terminal. The insulation is provided between core and windings and between two windings. The insulation type is the paper insulation & outer body covered by the plastic tap. The total weight of transformer is 12.24kg and the weight of core is 9.81kg. the copper wire which are use for transformer is 2.43kg.
[4]
P. Gómez, F. de León, and I. Hernández, “Impulse Response Analysis of Toroidal Core Distribution Transformers for Dielectric Design”, IEEE Transactions on Power Delivery, vol. 26, no. 2, April 2011, pp. 12311238.
[5]
F. de León, S. Purushothaman, and L. Qaseer, “Leakage Inductance Design of Toroidal Transformers by Sector Winding”, IEEE Transactions on Power Electronics, vol. 29, no. 1, January 2014, pp. 473480.
2.3 Toroidal Transformer Input & output:
[6]
Hernández, F. de León, and P. Gómez, “Design Formulas for the Leakage Inductance of Toroidal Distribution Transformers”, IEEE Transactions on Power Delivery, vol. 26, no. 4, October 2011, pp. 21972204.
[7]
UltraSIL polymerhoused Evolution (10 kA) IEEE surge arresters for MV systems to 36 kV, Technical Data 23599, Cooper Power Systems.
BIOGRAPHIES
Fig. 2.3: Toroidal Transformer input & output In this figure we can see that in input terminal we can apply 230volts. And as per our requirement it steps down the voltage to 110volts. That can we achieve by very efficient without losing a copper loss.
Name: Harshit R. Sawant Diploma in Elect. Engg. [Butler Polytechnic Institute, Vadodara] Pursuing Bachelors in Elect. Engg. [Vadodara Institute of Engineering, Kotambi]
Name: Keyur D. Patel Pursuing Bachelors in Elect. Engg. [Vadodara Institute of Engineering, Kotambi]
3. CONCLUSIONS The research perform for this project has demonstrate that it is possible to design build a utility grade distribution transformer in toroidal core. The gapless construction of toroidal transformer brings important advantages over the traditional design. It has been show that the higher efficiency compares the traditional shall type and core type transformer.
REFERENCES [1]
Energy Conservation Program for Commercial Equipment: Distribution Transformers Energy Conservation Standards, Department of Energy Final Rule, 10 CFR Part 431.
[2]
IEEE Standard General Requirements for DryType Distribution and Power Transformers, Including Those with SolidCast and/or Resin Encapsulated Windings, IEEE Std. C57.12.01, May 2006
[3]
S. Purushothaman and F. de León, “Heat Transfer Model for Toroidal Transformers”, Transactions on Power Delivery, vol. 27, no. 2, April 2012, pp. 813820.
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Impact Factor value: 6.171

Name: Rahi N. Tapare Diploma in Elect. Engg. [Parul Polytechnic Institute, Vadodara] Pursuing Bachelors in Elect. Engg. [Vadodara Institute of Engineering, Kotambi]
Name: Prof. Darshit S. Patel B.E. Degree in Electrical Engineering From Charutar Institute of Technology , Changa, Gujarat, India in 2007 and M.S. In Electrical Engineering from University Of Bridgeport, CT, USA in Dec.2010.He is currently an Assistant Professor in the Department of Electrical Engineering, Vadodara Institute Of Engineering, Vadodara, Gujarat. His research interests include Design of Rotating Machines , Transformers and Testing of electrical machines
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