INTERNATIONAL SCIENTIFIC JOURNAL "INDUSTRY 4.

0" WEB ISSN 2534-997X; PRINT ISSN 2543-8582

FEM 2D AND 3D DESIGN OF TRANSFORMER FOR CORE LOSSES

COMPUTATION
Assoc. prof. Dr. Sarac Vasilija
Faculty of Electrical Engineering – University “Goce Delcev”, R. Macedonia

[email protected]
Abstract: Accurate simulation and prediction of losses in power transformer is important during transformer lifetime but also during the
design stage. Paper presents the simulation model of transformer based of Finite Element Method that allows calculation of core losses and
magnetic flux density in transformer cross-section. Two different models are constructed for 2D and 3D simulation. Obtained results are
compared with experiments. Finally, flux density in both models is calculated and obtained results are presented for different time steps.
Keywords: CORE LOSSES, POWER TRANSFORMER, FEM MODELS, MAGNETIC FLUX DENSITY

and represent complicated geometry using irregular grids [8]-[9].

1. Introduction FEM solves the set of Maxwell equations for a given excitation and
Modeling of power transformers and their accurate simulation frequency. Transient simulation is performed by domain
has been always a challenging task for engineers worldwide. Power decomposition along time-axis (TDM-time decomposition method)
transformers are the most expensive element in energy distribution to solve all time steps simultaneously, instead solving a transient
networks therefore accurate prediction of transformer operation as problem time step by time step [7]. In both transformer models,
well as possible malfunctioning has been always an issue among boundary conditions are defined on object outer geometry as well as
engineers. Heindl et al. propose high frequency models of large properties of all materials. Magnetic core is characterized with B-H
power transformers required for analysis of transient interaction curve of magnetization and thin laminations. They are input in both
between the transformers and the power system [1]. Ozgonenel and transformer models (Fig. 2). Specific core losses P are input as well,
Kilic propose an algorithm and transformer model for identification and core losses are calculated for one specific frequency, in this
of different internal faults, which lead to transformer outage [2]. case 50 Hz (Fig. 3).
During recent years Finite Element Method (FEM) gained a
2.00
popularity for modeling various nonlinear materials and permanent
magnets under the variety of conditions, employing sinusoidal
waveforms and practically any other pulsed wave form of excitation 1.50

[3] –[5]. FEM has been used for calculating transformer parameters
B (tesla)

in cases when partial discharge in transformer winding occurs [6]. 1.00

In recent years, various powerful softwares have been developed for
calculation of transformer parameters, operating modes and
0.50
different type of losses [7]. Paper presents 2D and 3D model of
power transformer for calculating core losses and magnetic flux
density at transformer cross-section. Core losses are calculated at 0.00
0.00 5000.00 10000.00 15000.00
H (A_per_meter)
no-load for 50 Hz voltage supply, therefore only the low voltage
winding is energized with rated voltage. Calculations are based on Fig. 2 B-H curve of core laminations
data of three phase transformer 115/13.8 kV, 60 Hz and 30 MVA
with tested core losses of 23.7 kW.

Fig. 1 Transformer 2D and 3D model

Computer animation has been used for presenting the magnetic

flux density in core cross section. Flux density is calculated for
different time intervals. Knowledge of flux density allows parts of
transformer core close to the point of saturation to be detected and Fig. 3 P-B curve of core losses versus flux density
transformer construction to be modified in terms of avoiding
saturation of core, high losses and low efficiency factor. Traditionally, core loss Pc has been divided into two
components: hysteresis losses Ph and eddy current losses Pe.
2. FEM models According to the Steinmetz equation, measurement and calculation
Based on real transformer dimensions and geometry the FEM of core losses are normally made with sinusoidal flux density of
models have been constructed for 2D and 3D simulation of low varying magnitude-B and frequency-f. These measurements and
frequency transient electromagnetic fields. The basic procedure of calculations are based on the standard coil and frequently are
transient simulation includes spatial and temporal discretization of modeled by a two-term function of the form:
the physical equations. There are several approaches to do spatial
discretization: finite differences, finite elements and finite volumes. Pc = Ph + Pe = k h fB n + k c f 2 B 2 (1)
The finite element method is widely used in engineering practice
because it can model complex inhomgeneous, anisotropic materials

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INTERNATIONAL SCIENTIFIC JOURNAL "INDUSTRY 4.0" WEB ISSN 2534-997X; PRINT ISSN 2543-8582

kh, kc and n are the coefficients which depend on the lamination, In order magnetic flux density B to be calculated, magnetic vector
material thickness, conductivity as well as other factors [10]. This potential A must be found. For that purpose, the whole object
formula is applicable up to the maximum flux density of B of 1 T, geometry is divided into numerous elements, usually triangles,
which is not the case in electrical machines and transformers. where A is approximated by a simple function. Created mesh of
In this paper, calculation of core losses is done according to: finite elements in 2D and 3D model is presented in Fig. 5.

Pc = Ph + Pe + Pexcess = K1Bm2 + K 2 Bm1,5 (2)

Where the eddy current losses are:

Pe = k c ( fBm )2 (3)

The hystersis losses are:

Ph = k h fBm 2 (4)

and the excessive losses are:

Pexcess = ke ( fBm )1.5 (5)

Therefore:

K1 = k h f + k c f 2 (6) (a) Mesh at 2D model

K 2 = k e f 1.5 (7)

The eddy-current loss coefficient is calculated as:

d2
k c = π 2σ (8)
6
Where σ is the conductivity and d is is is the thickness of one
lamination sheet. Coefficients K1 and K2 are obtained from
minimization of function:

(
f K1K 2 = ∑ Pνi − K1Bmi
2
+ K 2 Bmi)
1.5
[ ( )]2
= min (9)
(b) Mesh at 3D model
Fig. 5 Mesh at transformer models

Where Pνi, Bmi- the i-th point of the data on the measured loss
characteristic curve. The other two loss coefficients are: The 3-D magnetic transient solver can calculate [7]:

k h = K1 − k c f 0 2 / f 0 ( ) - the end-field effect as end-winding field effect and/or the

influence of different stack lengths on the overall losses.
k e = K 2 / f 01.5 (10) - core loss prediction due to a magnetic field component normal
to the lamination stack.
where f0 is the testing frequency for loss curve.
- effect of time-controlled current/voltage wave forms on
In this case, core losses are input in transformer models as total
operating point conditions.
losses for one specific frequency 50 Hz or 60 Hz (P-B curve). Since
the starting transformer model is for 60 Hz, besides changing the - eddy-current effects induced into conductive materials.
model frequency to 50 Hz, the amplitude of input phase voltage
( 13.8 ⋅ 2 / 3 kV) is reduced for factor 5/6, as well as power 3. Results and discussions
rating of the transformer. This keeps the same currents in windings Transient simulation is run for predefined time and time step.
and avoids transformer overheating when 60 Hz transformer is run Simulation results of core losses are obtained for two different
with 50 Hz voltage supply. For both frequencies, power losses are frequencies 50 Hz and 60 Hz and for 2D and 3D model. Core losses
calculated. For core losses, only a single energized winding needs to are averaged over the time. For all above-mentioned variants, they
be considered. An exponentially increasing voltage source is are presented in Figs. 6. and 7.
applied in order to eliminate inrush current and the needs for an
unreasonably long simulation time (Fig. 4).
XY Plot 3 Maxwell2DDesign-3 ANSOFT
XY Plot 2 Maxwell2DDesign-3 ANSOFT 30.00 Curve Info avg
10.00 Curve Info CoreLoss
19.9772
InputVoltage(WindingA) Setup1 : Transient
Setup1 : Transient
7.50 25.00
InputVoltage(WindingB)
Setup1 : Transient
InputVoltage(WindingC)
5.00 Setup1 : Transient
20.00
CoreLoss [kW]

2.50
Input voltage [kV]

15.00
0.00

-2.50 10.00

-5.00
5.00

-7.50

0.00
-10.00 0.00 20.00 40.00 60.00 80.00 100.00
0.00 20.00 40.00 60.00 80.00 100.00 Time [ms]
Time [ms]

(a) core losses at 50 Hz

Fig. 4 Input voltage at 50 Hz

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INTERNATIONAL SCIENTIFIC JOURNAL "INDUSTRY 4.0" WEB ISSN 2534-997X; PRINT ISSN 2543-8582

XY Plot 3 Maxwell2DDesign1
35.00
Curve Info avg
ANSOFT
empirical formulas, gives only approximate values of the flux
30.00
CoreLoss
Setup1 : Transient
25.2213
density at different parts of the machine. Accurate predication of the
flux density at different parts of the machines is important in the
25.00
design process for predicting so-called week parts of the machine
where core material is close to the point of saturation (knee of the
CoreLoss [kW]

20.00

B-H curve). Operation of the machine near to the point of core

15.00
saturation increases the losses, heat dissipation and reduces the
10.00 efficiency. Therefore, flux density is analyzed at different time
5.00
intervals for both models and both frequencies. Fig. 8 presents the
results for 2D model and Fig. 9 for 3D model respectively.
0.00
0.00 20.00 40.00 60.00 80.00 100.00
Time [ms]

(b) core losses at 60 Hz

Fig. 6 Core loses at 2D model

XY Plot 3 Maxwell3DDesign1 ANSOFT

30.00 Curve Info avg
CoreLoss
22.1852
Setup1 : Transient

25.00

20.00
CoreLoss [kW]

15.00

10.00

5.00

(a) flux density at 50 Hz

0.00
0.00 20.00 40.00 60.00 80.00 100.00
Time [ms]

(a) core losses at 50 Hz

XY Plot 3 Maxwell3DDesign1 ANSOFT
30.00
Curve Info avg
CoreLoss
23.1774
Setup1 : Transient

25.00

20.00
CoreLoss [kW]

15.00

10.00

5.00

0.00
(b) flux density at 60 Hz
0.00 20.00 40.00 60.00 80.00 100.00
Time [ms] Fig.8. Flux density distribution at 2D transformer model
(b) core losses at 60 Hz
Fig. 7 Core losses at 3D model

Core losses are averaged over the time interval from 80 to 100 ms.
Their values in different models and frequencies are presented in
Table 1.
Table 1: Core losses at different models and frequencies
2D model 3D model
50 Hz 50 Hz 50 Hz 60 Hz
Core
losses 19.9 25.2 22.1 23.1
[kW]
(a) flux density at 50 Hz

Comparison of results from Table 1 shows that there is a slight

difference between the obtained values of core losses in 2D and 3D
model of the transformer. The tested core losses at 60 Hz are 23.7
kW. Obtained results in both transformer models are close to the
measured value of losses, which confirms the accuracy of presented
models. Models are simulated for both frequencies of supply
voltage 50 Hz and 60 Hz. As expected core losses are lower at
frequency 50 Hz i.e. they should decrease approximately by factor
5/6. FEM model cannot consider all of the physical and
manufacturing core loss effects in laminated core. These effects
include mechanical stress on laminations, edge burr losses, step gap
fringing flux, circulating currents, and variations in sheet loss
(a) flux density at 60 Hz
values [7].
Fig. 9. Flux density distribution at 3D transformer model
Over the years, FEM proved to be a useful tool toll in numerical
calculation of different electromagnetic quantities. It is especially
useful in calculation of magnetic flux density in machines cross- From presented results in Figs. 8 and 9 it is evident that for both
section. Calculation of the magnetic flux density, based on frequencies and in both models, transformer operates at no –load,

121 YEAR II, ISSUE 3, P.P. 119-122 (2017)

INTERNATIONAL SCIENTIFIC JOURNAL "INDUSTRY 4.0" WEB ISSN 2534-997X; PRINT ISSN 2543-8582

with flux density distribution in core cross-section well bellow the [3] G. H. Chitaliya, S. K. Joshi: Finite Element Method for
saturation point (approximately 2 T- Fig. 2). As expected due to the Designing and Analysis of the Transformer- A Retrospective,
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[4] S.M.H. Hosseini, S.M. Enjavi Madar, M. Vakilian: Using the
4. Conclusion finite element method to calculate parameters for a detailed
Knowing the losses in electrical devices is important in terms of model of transformer winding for partial discharge research,
the exploitation of the device but also in terms of its design. Turkish journal of electrical engineering and computer science,
Therefore, accurate simulation models for anticipating the losses are vol. 23, no. 3 , 2015, pp. 709-718.
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[5] E. Schmidt : Finite element analysis of electrical machines and
devices. Simulation model of transformer based on FEM is
transformer: State of the art and future trends, COMPEL-The
presented. Obtained 2D and 3D models allow calculation of core
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losses for three-phase symmetrical power supply. Models are
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powered with 50 and 60 Hz power supply. Due to lower frequency
1899-1913.
losses are reduced at 50 Hz , compared to 60 Hz power supply. Flux
density distribution in transformer cross-section is calculated as [6] Y. Wang, J. Pan, M. Jin: Finite Element Modeling of the
well. Obtained results in all models have proved that transformer at Vibration of a Power Transformer, Proceedings of
no-load is operating well beyond the point of core saturation. ACOUSTIC 2-4 November, Australia , 2011, pp. 1-7.
Further research will be focused on calculating the core and copper
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