Winding calculation notes

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The winding copper calculation note is a critical document used during the transformer design phase
to calculate the amount of copper required for the windings of the transformer. These calculations are
essential for determining the size and weight of the copper wire, and they help ensure that the
transformer meets electrical and thermal performance criteria, as well as cost and efficiency targets.
Here is an outline of the typical steps and considerations involved in the winding copper calculation:
1. Determine Transformer Specifications

Rated Power (S): The transformer's power rating (in kVA or MVA).
Rated Voltage: Primary and secondary voltage ratings (in kV).
Rated Current (I): The current on the primary and secondary windings, calculated as:
S
I=
3×V

Where:
S is the apparent power (kVA or MVA).

V is the voltage (kV).
3 accounts for the three-phase transformer (in case of three-phase transformer).

2. Number of Turns per Coil

Calculate the number of turns required for both the primary and secondary windings using the
voltage and the flux density.
Formula for number of turns (N):
Vrms × 103
N=

4.44 × f × B × A

Where:
Vrms is the rated voltage.

f is the frequency of operation (in Hz).

B is the peak magnetic flux density (in Tesla).
A is the cross-sectional area of the core (in mm²).
3. Wire Gauge Selection

Current Carrying Capacity: The gauge of the wire is chosen based on the amount of current the
winding will carry. Copper wires are rated for specific current capacities (amperes per square
millimeter of conductor).
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The cross-sectional area of the wire can be determined based on the current using the following
equation:
I
Awire =
J

Where:
I is the current to be carried by the winding (in Amps).

J is the current density (A/mm²), which depends on the wire material and thermal conditions.
4. Winding Configuration
Layered Winding: For large transformers, windings are often constructed in layers, with each layer
consisting of multiple turns of copper wire.
Conductor Arrangement: The wire could be arranged in a single-layer or multi-layer coil
configuration.
Insulation: Insulation thickness should also be taken into account for determining the effective
wire diameter.
Conductor Fill Factor: This factor accounts for the fact that windings are not perfectly packed and
that there is some air space between wires due to insulation. It typically ranges from 0.6 to 0.8.
5. Copper Losses (Core Losses)

AC Resistance of Copper: Copper has a resistance that increases with frequency. The skin effect
(the tendency for alternating current to flow more on the surface of the conductor at higher
frequencies) should be considered.
AC Resistance Calculation:
ρ×l
RAC =
A

Where:
ρ is the resistivity of copper (approximately 1.68 × 10−8 Ω ⋅ m).
l is the length of the wire.
A is the cross-sectional area of the wire.
Copper Losses in Windings: The copper loss is proportional to the square of the current and the
resistance of the windings.
Pcopper = I 2 × RAC

6. Total Copper Weight Calculation
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Length of Copper Wire: The total length of wire used in both primary and secondary windings
can be calculated by:
Lwire = N × Mean Turn Length

Where the mean turn length is the average length of one turn of the winding.
Weight of Copper: The weight of the copper used in the winding is then calculated by:
Wcopper = ρcopper × Lwire × Awire

Where:
3
ρcopper is the density of copper (approximately 8.96 g/cm ).

7. Calculation Example:
For a specific transformer, you might perform the following example:
Given:
Rated power (S) = 100 MVA
Primary voltage (V1) = 110 kV
Secondary voltage (V2) = 33 kV
Frequency (f) = 50 Hz
Flux density (B) = 1.5 Tesla
Core area (A) = 1200 cm²
Copper wire current density (J) = 3 A/mm²
Step 1: Calculate the rated current (I). For the primary winding:
S 100 × 103
Iprimary = = = 523.8 A
3 × Vprimary 3 × 110

For the secondary winding:
S 100 × 103
Isecondary = = = 1754.6 A
3 × Vsecondary 3 × 33

Step 2: Calculate the number of turns for primary and secondary windings (assuming values for f , B
, and A).
Use the formula for the number of turns per coil.
Step 3: Calculate the copper wire size.

Using the current carrying capacity of the wire (using the I value and J ), calculate the required
wire cross-sectional area Awire .
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Step 4: Calculate the total copper weight.

Find the length of the copper wire from the number of turns and the mean turn length, then
multiply by the wire cross-section area and the copper density to find the total weight.
Conclusion:
The winding copper calculation note is a critical part of transformer design that ensures the proper
selection of copper wire for windings, optimized for electrical performance and efficiency. This
document helps determine the amount of copper required based on the transformer specifications,
which also impacts the design, thermal management, and overall cost of the transformer.

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12/2/24, 9:33 AM ChatGPT

1. Determine Transformer Specifications

S is the apparent power (kVA or MVA).

2. Number of Turns per Coil

Vrms is the rated voltage.

f is the frequency of operation (in Hz).

3. Wire Gauge Selection

I is the current to be carried by the winding (in Amps).

5. Copper Losses (Core Losses)

6. Total Copper Weight Calculation

Lwire = N × Mean Turn Length

Wcopper = ρcopper × Lwire × Awire

For the secondary winding:

Step 3: Calculate the copper wire size.

Step 4: Calculate the total copper weight.

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