Design 20 Formulas
Design 20 Formulas
Design 20 Formulas
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Pablo Gómez
Western Michigan University
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(1)
Substituting (4a) into (5) and performing the integral, one (12)
obtains
C. Corners (Sections IV and V)
For the corners, the same peak values for the magnetic field
(7) defined for the internal and external vertical parts are
considered as given by (4a) and (4b). The trapezoidal distribu-
The leakage inductance for Section II is computed in a similar tion of is around the corner, so it was necessary to perform
manner as the integral around its periphery denoted by (from 0 to );
the leakage inductance for the internal corners is obtained from
(13), shown at the bottom of the page.
(8) Solving (13), it follows that:
(14)
B. Horizontal Parts (Section III)
The top and bottom parts have the same field distribution; where
see Fig. 3(c). The value of at the interwinding insulation is
computed from Ampere’s Law as follows: (15a)
(15b)
(9) (15c)
(10)
(13)
HERNÁNDEZ et al.: DESIGN FORMULAS FOR LEAKAGE INDUCTANCE 2201
TABLE I TABLE II
COEFFICIENTS FOR THE DIFFERENT COMPONENTS OF THE LEAKAGE DESIGN PARAMETERS FOR SINGLE-PHASE TOROIDAL TRANSFORMERS
INDUCTANCE FORMULA (17)
TABLE III
Similarly, the leakage inductance for the external corners is PARAMETERS COMPUTED FOR SINGLE-PHASE TOROIDAL TRANSFORMERS
computed as
(16)
D. Generalized Expression
One can appreciate that (7), (8), (12), (14), and (16) have a
similar form. Therefore, a generalized expression for the cal-
culation of the contribution to the leakage inductance of each TABLE IV
IMPEDANCE DATA FOR THE SINGLE-PHASE TRANSFORMERS FROM[13]
section can be obtained as follows:
(17)
(18)
where is the increased space in the interwinding region. The
leakage inductance corresponding to the horizontal components
of the winding (regions 3 and 4), given by (12), is also modified,
resulting in the following expression:
(19)
Fig. 6(a) shows the variation of the leakage inductance with the
interwinding space for the four transformer ratings under study.
One can appreciate that increasing the interwinding spacing in-
creases the leakage inductance by a relatively modest amount.
The values have been normalized with respect to the minimum
interwinding space needed for insulation purposes (1 mm). Fig. 6. Variation of the leakage inductance: (a) Calculated for four different
ratings of toroidal distribution transformers. (b) Comparison of the analytical
The results from the formulas of this paper against FEM are results with FEM for a 25-kVA toroidal transformer.
compared in Fig. 6(b) for the transformer 25 kVA. One can ap-
preciate a very good match between the formulas and FEM (dif-
ferences of about 4%).
external winding has a longer mean length (adding production
As a conclusion of this section, one can observe that the tech-
cost and operation losses).
nique of increasing interwinding spacing is effective when rel-
atively small increments of the leakage inductance are needed.
B. Ferromagnetic Inserts
However, when large increments are sought, a different tech-
nique is necessary. Furthermore, adding larger spaces than re- The second technique proposed in this paper to increase the
quired for insulation purposes adds cost and weight to the trans- leakage inductance is to augment the permeability of the mate-
former. The most significant negative consequence is that the rial in the leakage region. By inserting ferromagnetic material
HERNÁNDEZ et al.: DESIGN FORMULAS FOR LEAKAGE INDUCTANCE 2203
(20)
where is the thickness of the region occupied by the fer-
romagnetic material and is its relative permeability. The Fig. 8. Increase of the leakage inductance. (a) Inserting four different ferro-
leakage inductance for the horizontal components of the magnetic materials between the windings. (b) Comparison of results between
formulas and FEM for the 25-kVA transformer.
winding is modified in a similar fashion as (12), yielding:
(21) an RLC meter (7600 Precision LCR meter) available in the lab.
This meter uses an ac signal of 2 V at 60 Hz and it gives the
By adding material with high relative permeability , the equivalent series R-L circuit of the transformer directly. In all
value of the leakage inductance can be magnified by a large cases, the secondary windings of the transformers are shorted
factor. When using this technique, care must be taken to avoid and the primary windings are connected to the source.
saturation of the thin core placed between the windings. Table V shows the comparison of the measurements on the
Different ferromagnetic materials [15] were considered for five prototypes against finite elements simulations and the for-
the simulations performed to validate this technique. Fig. 8(a) mulas of this paper. One can appreciate that for most cases,
shows the variation of leakage inductance with thickness for ma- the results are very close between the four different methods
terials with different permeability. The plot is given in per unit (SC, RLC meter, FEM, and formulas). The differences are, in
(p.u.), normalized to the minimum insulation space and perme- general, less than 3%. The sole exception is the SC measure-
ability of air . A comparison between the results of the for- ment of the 300-VA double-core transformer with 8.47% dif-
mulation and FEM is shown in Fig. 8(b). One can notice that the ference. This transformer was opened and unwound. We found
differences are very small. that the external (powder) core was fractured. Therefore, the ef-
fective permeability of this core was reduced by the irregular
(unintended) air gap, explaining why the measurements gave a
VI. EXPERIMENTAL VERIFICATION
slightly smaller leakage inductance when compared with FEM
With the purpose of validating the formulas proposed in this and the formulas.
paper and the FEM simulations, a set of prototypes was built These experiments not only corroborate the accuracy of the
with ratings of 150 VA, 300 VA, 1 kVA, 2 kVA, and 4 kVA. The calculation method proposed in this paper, but also confirm the
leakage inductance was measured by applying two methods: applicability of ferromagnetic inserts to increase the leakage in-
1) using the standardized short-circuit (SC) test and 2) using ductance when large leakage is necessary.
2204 IEEE TRANSACTIONS ON POWER DELIVERY, VOL. 26, NO. 4, OCTOBER 2011