TO DESIGN AND CONSTRUCT THE SET UP OF THE

TRANSFORMER

A project submitted for the partial fulfillment of the requirement for

the grade XII Science in
Physics

GURUKUL ACADEMY
National Education Board (NEB)
Ghorahi-15, Dang, Nepal
2081-11-17

Submitted to: Submitted By:

Mr. Ramesh Chaudhary Arjun Adhikari
Department of Physics Grade: XII(AB)
Roll No. 08
 CERTIFICATE OF APPROVAL

This project entitled “TO DESIGN AND CONSTRUCT THE SET

UP OF THE TRANSFORMER” submitted by ARJUN ADHIKARI
under the supervision of MR. RAMESH CHAUDHARY is approved
for the partial fulfillment of the requirement of physics in grade XII.
This report has not been submitted in any other school and colleges
previously.

Supervisor
Mr. Ramesh Chaudhary
Department of Physics
GURUKUL ACADEMY
 RECOMMENDATION LETTER

This is to certify that the project work entitled “TO DESIGN AND
CONSTRUCT THE SET UP OF THE TRANSFORMER”had been
carried out by ARJUN ADHIKARI as a partial fulfillment for the
requirement of grade XII under my supervision. To thebest of my
knowledge, this work has not been submitted to any other purpose in
this college.

Supervisor
Department of Physics
GURUKUL ACADEMY
 DECLARATION

I, ARJUN ADHIKARI hereby declare that the work present herein is genuine
work done practically by me and has not been published somewhere for the
requirement of grade XII. Any literature, data or works done by others,
presented in this project are cited, has been given due acknowledgement and
listed in the reference section.

ARJUN ADHIKARI
Grade: XII
GURUKUL ACADEMY
 ACKNOWLEDGEMENT

I would like to express my deepest appreciation to all those who had

helped me to complete this project. Special thanks of gratitude to our
subject teacher and project guide Mr. Ramesh Chaudhary (Subject
teacher) Mr. SachinPariyar (lab-incharge),whose contribution in
stimulating suggestions and encouragement helped me to coordinate this
project, especially in writing this report. Furthermore, I would also like
to acknowledge with much appreciation the crucial role of other
teachers, who gave me encouragement and advice to make my report
effective named “TO DESIGN AND CONSTRUCT THE SET UP OF
THE TRANSFORMER”. Special thanks go to all my colleagues for
their encouragement and positive response towards my project. I would
like to extend my acknowledgements to all the sources for their
authentic material.

ARJUN ADHIKARI
 ABSTRACT

This project focuses on the design and construction of a transformer setup, aimed
at understanding and applying key principles of electrical power transmission. The
primary goal is to create a working model of a transformer, which efficiently steps
up or steps down voltage levels while ensuring minimal energy loss. The design
phase involves selecting appropriate materials for the core, windings, and
insulation, based on electrical characteristics and mechanical stability. The
construction phase emphasizes precision in winding the coils, assembling the
core, and integrating safety mechanisms to prevent overheating and electrical
faults. Additionally, the setup will be tested for functionality, efficiency, and
operational safety. This project provides a comprehensive understanding of
transformer operation, design considerations, and the practical aspects of
electrical engineering
 TABLE OF CONTENT

TRANSFORMER…………………………………………………………………………………………………………………………………… 1

TYPES OF TRANSFORMER…………………………………………………………………………………………………………………………2

TRANSFORMER DESIGN OVERVIEW…………………………………………………………………………………………………………3

CONCLUSION…………………………………………………………………………………………………………………………………………4

REFRENCES…………………………………………………………………………………………………………………………………………..5
 INTRODUCTION
Transformer
Electrical transformer is a static electrical machine which transforms electrical power from one
circuit toanother circuit, without changing the frequency. Transformer can increase or decrease
the voltage withcorresponding decrease or increase in current.

Working principle of transformer

The basic principle behind working of a
transformer is the phenomenon of
mutual induction between two
windings linked by common magnetic
flux. The figure at right shows the
simplest form of a transformer
.Basically a transformer consists of two
inductive coils; primary winding and
secondary winding. The coils are
electrically separated but magnetically
linked to each other. When, primary
winding is connected to a source of alternating voltage, alternating magnetic flux
is produced around the winding. The core provides magnetic path for the flux, to
get linked with the secondary winding. Most of the flux gets linked with the
secondary winding which is called as 'useful flux' or main 'flux', and the flux which
does not get linked with secondary winding is called as 'leakage flux'. As the flux
produced is alternating (the direction of it is continuously changing), EM gets
induced in the secondary winding according to Faraday's law of electromagnetic
induction. This emf IS called 'mutually induced emf', and the frequency of
mutually induced emf is same as that of supplied emf. If the secondary winding is
closed circuit, then mutually induced current flows through it, and hence the
electrical energy is transferred from one circuit (primary) to another circuit
(secondary)
 TYPES OF TRANSFORMER
Transformers can be classified on different basis, like types of construction, types
of cooling etc. (A) On the basis of construction, transformers can be classified into
two types as; (i) Core type transformer and (ii) Shell type transformer, which are
described below

(i) Core type transformer

In core type transformer, windings are cylindrical former wound, mounted on the core limbs as
shown in thefigure above. The cylindrical coils have different layers and each layer is insulated
from each other. Materialslike paper, cloth or mica can be used for insulation. Low voltage
windings are placed nearer to the core, as theyare easier to insulate.

(ii) Shell type transformer

The coils are former wound and mounted in layers stacked with insulation between them. A
shell type transformer may have simple rectangular form (as shown in above fig), or it may have
a distributed form.
 TRANSFORMER DESIGN OVERVIEW
The design of a transformer primarily focuses on optimizing its performance,
efficiency, and safety while meeting specific voltage and current requirements.
The main factors to consider during the design phase include:

Voltage Ratings: Determining the primary (input) and secondary (output) voltages.
Power Rating: Based on the application, the transformer must be designed to
handle a certain amount of electrical power, typically measured in kilovolt-
amperes (kVA).
Frequency: Most transformers are designed for a standard frequency of 50 Hz or
60 Hz, depending on the region.
Efficiency: Minimizing losses, such as core loss (hysteresis and eddy current losses)
and copper losses (due to resistance of windings).
Impedance: For proper load sharing and fault tolerance.
Cooling Method: Transformers generate heat during operation, and their cooling
design (oil, air, or forced oil) plays a crucial role in maintaining efficiency and
preventing damage.
Key Transformer Components:
Core: Made of laminated sheets of silicon steel to reduce eddy currents and
minimize energy losses.
Windings: Conductive coils made of copper or aluminum, wound around the core
to create the magnetic field.
Insulation: Materials like paper, oil, or synthetic materials used to electrically
isolate the windings and prevent short circuits.
Tap Changer: A mechanism that allows voltage adjustments on the secondary
side, depending on load variations.
2. Design Process
a) Core Design
The core of a transformer provides the magnetic path for energy transfer between
the primary and secondary windings. It is designed to handle the maximum flux
density while minimizing core losses. The core shape could be:
Rectangular core
Toroidal (donut-shaped) core (less common but highly efficient)
Core material is typically silicon steel, chosen for its high magnetic permeability
and low hysteresis loss. The size of the core is determined by the rated power and
operating voltage.

b) Winding Design
The primary and secondary windings must be designed to handle the rated
current without overheating. Factors such as the number of turns of wire, wire
gauge, and insulation type are considered to minimize losses and provide
adequate mechanical strength.

Turns Ratio: The number of turns in the primary winding divided by the number of
turns in the secondary winding determines the voltage ratio.

Conductor Selection: Copper or aluminum is used for winding conductors. Copper

is preferred for its lower resistance, but aluminum is cheaper and lighter.

c) Cooling System Design

Transformers generate heat during operation, and cooling is essential to maintain
efficiency and extend operational life. Depending on the design and power rating,
cooling methods include:
Oil Cooling: Common in large transformers, where oil (such as mineral oil) is used
to both insulate and cool the transformer.
Air Cooling: Used in smaller transformers, where air or forced air circulation is
used for cooling.
Hybrid Cooling: Combines oil and air cooling for medium-sized transformers.
d) Insulation System
The insulation system isolates the windings to prevent electrical shorts and
manage heat dissipation. Types of insulation include:

Paper-based insulation: Used in large transformers, it’s often impregnated with oil
to provide both insulation and cooling.
Synthetic insulation: Modern transformers use synthetic insulation materials like
Nomex or polyester for better thermal performance.
e) Protection and Control Systems
Transformers are equipped with protection devices to prevent damage from faults
or overloads. These include:

Circuit Breakers: To disconnect the transformer from the system in case of a fault.
Relays: To monitor the condition of the transformer and provide early warnings of
potential failures.
Fuses: To protect against short-circuit conditions.
3. Construction Setup
The construction of a transformer involves several key steps, with each focusing
on precision and safety. The process typically includes:
a) Manufacturing of Core
The core is constructed from thin sheets of high-quality silicon steel. These sheets
are stacked and laminated to form a solid core structure. The lamination reduces
eddy currents, which helps in minimizing energy loss.

b) Winding Process
Winding is carried out using precise machinery to ensure the correct number of
turns and placement of copper or aluminum wire. The wire is insulated with layers
of varnish, paper, or synthetic materials. The windings are then placed over the
core in a tightly wound manner to ensure optimal efficiency.

c) Insulation Application
The windings are coated with insulating materials, followed by the impregnation
of oil or resin in some cases. This insulation ensures electrical safety and heat
dissipation.

d) Assembly of Components
Once the core and windings are ready, they are assembled into a transformer
tank. The windings are placed concentrically around the core, and a tap changer is
installed to allow voltage adjustments. The transformer tank is then filled with oil
or other insulating fluid.

e) Testing and Quality Assurance

The transformer undergoes rigorous testing to ensure it meets the specified
parameters. Common tests include:
4. Conclusion
The design and construction of a transformer require precise calculations, quality
materials, and effective manufacturing techniques. The core, windings, insulation,
cooling systems, and protective mechanisms are all carefully designed to ensure
efficient operation, longevity, and safety. Effective transformer design leads to
improved energy transmission, minimized power loss, and better electrical
distribution. The construction setup emphasizes the importance of attention to
detail during the winding, assembly, and testing stages to ensure the final product
meets both performance and safety standards.

REFRENCES
https://chatgpt.com/
https://byjus.com/jee/transformer/
tps://en.wikipedia.org/wiki/Transformer