One of the main design challenges for power transformers is ensuring that the transformer meets the required performance specifications, including basic characteristics such as voltage regulation and efficiency. However, designers must also consider issues such as magnetic flux leakage, which can lead to localized stray loss in the transformer tank. This can result in increased heating and reduced efficiency, as well as potential safety hazards.
Another important consideration for power transformer design is the dielectric strength of the coil. The dielectric strength is a measure of the maximum electric field that the insulation surrounding the coil can withstand without breaking down. Designers must carefully evaluate the electric field distribution within the transformer to ensure that the coil can withstand the required voltages without failing.
The arrangement of the core and coil within the transformer also has an impact on vibration and noise levels. Unbalanced magnetic forces can cause the transformer to vibrate, which can lead to increased noise levels and potentially reduce the lifespan of the transformer.
To address these challenges, our engineers use a combination of analytical methods and simulation tools such as FEA and electromagnetic simulation software to analyze and optimize power transformer designs. These tools allow our designers to evaluate the magnetic and electric field distributions within the transformer, identify potential sources of stray loss and vibration, and optimize the transformer design to meet performance specifications and reduce maintenance requirements.
