Transformer design and analysis using ANSYS Maxwell

I'm trying to simulate a three phase core type transformer in Maxwell. Lack of a proper tutorial/resource is hindering my progress. I've designed the transformer from scratch. All the geometric parameters , flux density , current, no. of turns in the coils etc. While I can do the CAD part , the electromagnetic part is troubling me. Here's what I plan on doing :

1. Visualise the 'flow' of magnetic flux in the core for several cycles of an AC voltage excitation given to the coils. Animation also included.

2. Use transient solver to calculate the core loss. I will then export the data to Ansys Workbench and plot the temperature rise in the core due to the loss.


With regards to goal 1, i have no idea how to proceed. I've only done magnetostatic analysis with DC excitation and I have no idea how to provide a desired AC excitation to the coils. I've seen some video tutorials of how to do this stuff, but they dont use cylindrical concentric windings like i plan to do. Any pointers? I'm lost here. The closest i could get was to assign a winding to the coils and specify no. of turns for the hv and lv windings. A dead end after that. Have no idea what solver to use or how to go around plotting the flux variation. Any help would be appreciated.
Thanks!

CRGOS laminations come in various costs by thickness and watts per kg loss with various max Field strength like 1.2T or 1.9T. Abrupt faults cause remenance and when reclosed, the field saturates according to probable phase and margin.

There are standards if you search on what criteria to design to depending on the industrial application, PF, load balance and many other factors. I suggest you read more online books on dry transformers.

I'm sorry I should've mentioned this in the post. I've actually designed the transformer according to standard. I've used techniques from a machine design course we were taught a few semesters ago.

The machine is a 25kVA, 11kV/220 V, delta-star, core type distribution transformer.
The max flux density is 1.0 Wb/m^2.
The limbs have a cruciform cross section and the yokes are rectangular.
Core material is hot rolled silicon steel grade 92.
Specific iron loss at this flux density is 1.2 W/kg.
The density of laminations is taken as 7.6x10^3 kg/m^3 and the lamination thickness is 0.25 mm.
A design constraint is that the temperature rise of the core shouldn't exceed 45° C.
I have every aspect of the transformer calculated , like the currents , flux, core loss, no. of turns of the winding, leakage reactance, resistance of the winding etc. I just have to verify these parameters using software.

While I do have a rough cobbled together solution from posts on other forums, i consider edaboard a standard. It has never failed me in the past. So your help is appreciated. Thanks!

Did you factor losses of 5th and 3rd harmonics which may be significant under certain initial and load conditions.,Remenance and PF and THD of load, neutral current harmonics etc?

Did you do a stress analysis for a SC event on windings and structure? Or a 1.6cm earthquake at 1 Hz or the fragility limit for v(f), g(f) for transport? HaVe you any experience on dielectric spectal density coefficents or Partial Discharge that can be affected by contamination in silicate iron dust, moisture, sharp edges, process quality, winding vibrations and design margin? What strength margin is in the tank design to implosion from partial vacuum cleaning to remove moist air bubbles in oil? etc etc.b What requirements do you have to achieve low acoustic output for magneto stiction,laminate gaps,winding tension? Are you using sheet copper, alum, or round wire in secondary?

I don't need the answers, these are just questions I might ask in a design review.


For example the CRGOS laminate is a series of silicate insulated steel sheets like capacitors in series , each several microfarads and gighms if perfectly clean on the edges, but many factories are sloppy and the edge burrs and dust can shunt the steel resulting in PD, Undetected failures from Megger results and shunted edges causing fringe losses etc.?

You won't find this in simulators, but by experience.mBy the way, my experience on transformer design is nearly nil, but with 35 yrs in physics, chemistry and EE magnetics and electronic design I discovered a lot of undetected issues causing epidemic H2 genration failures in the field in a couple months recently related to the above and more.

You may not find many here with the right experience in this field here, (pun intended) but I only offer what I know for sure. Meanwhile MTBF of many small DT's continues to decline due to missing experience for forensic defects. Read more about design from Power Eng. Design by Dr. Rohan in Asia and practical experience from online forums about Transformers exclusively like LinkedIn or ABB blogs.

For this class of DT's fierce competition drives down the cost of dollars per KVA, meanwhile often they are under-engineered, and balancing margin to failure and cost is a delicate economic engineering challenge.

That being said, many are duplicates of a 50 yr old design with better materials and processing yet still may have worse MTBF of 10 yrs instead of 30 to 50 yrs from overlooking the above and other issues.

This is also a challenge.