International Conference on Future of Engineering Systems and Technologies IOP Publishing

Journal of Physics: Conference Series 1478 (2020) 012029 doi:10.1088/1742-6596/1478/1/012029

Assessment of the use of FEM for computation of

Electromagnetic Forces, Losses and Design of Transformers

Vibhuti1, Genius Walia2 and Deepika Bhalla3

Department of Electrical Engineering, Guru Kashi University, Talwandi Sabo, India
Department of Physics, Guru Kashi University, Talwandi Sabo, India
Department of Electrical Engineering, IKG Punjab Tecinal University, Jalandhar, India

E-mail: vibhu18rehalia@gmail.com

Abstract. This paper reviews the published work on power transformers for assessment of the
electrical, magnetic losses, and electromagnetic forces produced during normal and short circuit
conditions. The different methods used are analytical method, integral equation method,
boundary element method, and finite element method (FEM). The copper losses and eddy
currents within the copper conductors/windings need to be assessed to estimate the heat generate
and compute the efficiency. The knowledge of the eddy current losses in the core and stray
losses in each component of the transformer can help in the design improvement. Earlier 2D
FEM and now 3D FEM has been used to evaluate the electromagnetic flux under normal
conditions, the effect of the in-rush phenomenon, assessment of mechanical strength of
windings, insulation, computation of short circuit forces and need of the mechanical support
components during fault conditions. This paper gives an overview of the work done on the
computation of electromagnetic forces, losses, and design of transformers using FEM to assess
the scope for further work.

Keywords: Electromagnetic forces, Finite element method, Losses, Short circuit current,
Transformers

1. Introduction
In a power system for transmission and also for distribution, transformers are used for stepping up and
stepping down the voltage. Transformers are important components that make large power systems
possible. These are electrical devices that transform need-based voltage level and current value between
two electrical circuits linked with a common magnetic circuit. They transform the power from one
circuit to another by electromagnetic induction without a change in frequency and have no internal
moving parts. The types of transformer are classified according to their purpose, rating, use, and
construction. Proper design of the transformer is essential for the reliability of the power system where
it is installed. It has three main parts: namely, the primary winding which produces magnetic flux,
secondary winding that gives output power at a required voltage level and a magnetic core and
alternating voltage is applied to the primary winding. In this process, the power transferred between the
circuits remains constant and comparatively small losses occur. The transformer losses are the iron or
core loss which comprise of hysteresis loss and eddy current loss, the copper loss or ohmic loss in the
windings, along with these there are also present the stray loss and dielectric loss. Since the transformer
works on the principle of electromagnetic induction, electromagnetic forces are present. These forces
are of very small magnitude during normal operation but have tremendous magnitude during faults due
to the magnitude of the current in the windings.
This paper assesses the different technical publications on transformers based on the parts and types of
construction and losses. This review aims to recognize the use of 2D and 3D FEM for assessing the
different types of transformers with different ratings, different types of windings, the losses in

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International Conference on Future of Engineering Systems and Technologies IOP Publishing
Journal of Physics: Conference Series 1478 (2020) 012029 doi:10.1088/1742-6596/1478/1/012029

component, within windings, transposition of winding conductors, electromagnetic forces and design
of the transformer. Also, it is intended to assess the use of the FEM results for improvement of design
by reduction of stray losses and thermal analysis for the effect of overheating- its analysis to decrease
hot spot, core losses, the safety factor for of axial and radial forces. This paper intends to assess the
scope of future work on transformer electromagnetic forces, losses, and design improvement using
FEM.

2. Method of Transformer Performance Analysis

The methods that are used for transformer analysis transformer performance are FEM, the integral
equation method (IEM) and the boundary element method (BEM). FEM has been used for the analysis
of different types, various parts, analysis of electromagnetic forces, and thermal analysis of transformers
[1-16]. The integral equations have been used to analyze stray losses and leak magnetic flux [4, 17],
and the boundary element method has been used for the design of insulation [18]. The reactance model
of the transformer can be developed using FEM [19].
The finite element method is a way of solving complex problems like structure analysis, heat-transfer,
and electromagnetic field. Any physical problem can be expressed by the governing equation and
boundary conditions in the same partial differential equation. The partial differential equation is
difficult to solve, FEM converts the partial equations into the algebraic equation by raking
approximation that is easy to solve. FEM convert the domain into number of finite element and then
convert the partial differential equation into the algebraic equation and give result by taking into
consideration of the algebraic equation. FEM subdivides the structure on which analysis is to be carried
out into subdomains or small elements. The small elements are represented by a mesh. The mesh
created for a section of a three-phase transformer for 3 D and 2 D analysis is shown in figure 1 (a) and
(b)respectively.
Both 2D and 3D FEM simulation methods have been extensively used for the study of electromagnetic
forces, losses, circulating currents, and design of transformers [1,2,4,6-10,17-26]. 2D FEM analysis
[12-14,27,28] and 3D FEM analysis of transformers has been done [5,15,6,29-44]. Comparison of the
2Dand 3D results has also been done [38,41, 45] and both are found to give results that are close to
those obtained by the conventional analytical method [44] and those found by experiments [59].

(a) 2D Mesh (b) 3D Mesh

Figure 1. Mesh created by finite element method

3. Transformer Type and Rating

FEM has been used for the study of both single-phase transformer transformers [8, 34, 36, 44, 46] and
three-phase transformers [40,48]. Power transformers [4, 30-32, 35, 48-50] and distribution
transformer [51-53] have been analyzed using FEM. The ratings of power transformers considered in
different publications are 10 MVA [27], 28.333 MVA [44], 38 MVA [46], 40 MVA [47], 50 MVA
[55], 200 MVA [30], 240 MVA [48], 315 MVA [34] 360 MVA [56] and 420 MVA [32] and rating of
distribution transformers are 630 kVA [54], 1000 kVA [16], 2000 kVA [57]. Most of the work on
power and distribution transformer is for low frequency 50 Hz or 60 Hz [41, 54, 58], work has also
been done on medium frequency transformer [42] and high frequency [1]. Analysis of the shell type
[15] and core type [59] has also been carried out. Performance of dry type transformer [51], current
transformer [24], isolating transformer [60] has been assessed using FEM. The FEM results give a
good performance for both distribution and power transformers along with special purpose
transformers.
4. Transformer Losses

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International Conference on Future of Engineering Systems and Technologies IOP Publishing
Journal of Physics: Conference Series 1478 (2020) 012029 doi:10.1088/1742-6596/1478/1/012029

4.1 Copper Loss

Ohmic resistance of the winding of the transformer produces copper losses. For the primary and
secondary losses, the copper losses are I12 R1, I22 R2, where I1 and I2are the currents in the primary and
secondary winding2 and R1 and R2 are the resistance of the primary winding. Copper losses vary with
the load of the transformer. Total copper losses in the transformer are the sum of the losses in the
primary and secondary. Calculation and simulation of copper losses [41, 59] have been done as well.

4.2 Stray Loss

Analysis of stray losses [4, 6, 16, 22, 32, 33, 35, 37, 41, 42, 48, 57, 63, 64, 65]. Three-phase transformer
[29], and single-phase transformer [44] losses have been assessed. Stray losses have been analyzed for
power transformers [4, 33, 64] and distribution transformers [16,44,52,57]. The stray loss occurred in
metal structures and their values have been computed oil tank [18, 19, 31, 32, 34, 35, 64, 66]
upper/bottom frame [6], tie-plate [6,64], bushings [66], flanges [64]. For minimization of losses and
accurate calculations relating to absolute values, the most effective position of clamps and crossbars
are detected. [31] Transformer tank walls and fitting may be modeled accurately for the justification of
skin effect [67]. The computation of stray losses using FEM can be used to improve the transformer
efficiency by making changes in the design.

4.3 Eddy Current Loss

Eddy current losses caused by varying magnetic field inducing eddy currents in the lamination and
thus generating heat. Eddy current generates resistive losses that transform energy into heat. The eddy
current losses (Pe) are equal to KeBm2t2f2v. Where K is co-efficient of eddy current, Bm is a maximum
value of density (wb/m2), t is the thickness of lamination (m), f is the supply frequency (hertz) and v is
the volume of magnetic material (m3). Eddy currents also occur within winding conductors as well as
in other metallic parts where they create losses.
Different techniques like non-linear surface impedance methods [40], FEM [3, 13, 26, 38, 39] are used
for computation of circulating currents. Circulating current is calculated by the inductance matrix [25].
Calculation of circulating current losses using the analytical formulation has constraints, there has been
calculated using 2D FEM [13] and 3D FEM [39]. In transformer eddy current in clamping [39,68]
clamping frame [39] clamp plates [40] have been computed. Circulating current in a stranded conductor
depends upon the relative location of strands throughout the winding [69]. Circulating current losses
create proximity losses in the stator winding [43, 70]. Eddy currents in the coaxial winding have been
calculated using FEM [58]. Core losses at different excitation frequencies have been found [68]. Eddy
current losses have been investigated in power transformer [56], three-phase transformer [72]. These
have been found for round conductors [26] and stranded winding [69]. FEM can compute these losses
in the metallic parts and the windings as well. Eddy currents are also referred to as circulating currents
in literature. Transformer losses are assessed as no-load and load loss [71]. A comprehensive analysis
of the transformer losses is not available.

5. Transformer Windings
The transformer’s windings are generally of three types; namely layer type, disc type or spiral or helical
type.Transformer helical winding single layer/I- type[73-75] and double-layer/U-type [5, 12, 75-77]
U-type for low voltage winding [9,79], high voltage [27,42] and both low voltage and high voltage
winding [11,24,73] have been analyses FEM. Analysis of asymmetric winding [78] stranded winding
[69] has been carried out using FEM. To reduce proximity losses effectively transposition is done.
Study of the effect of transposition [43] and transposition optimized design is done [13, 79]. Ideal
transposition has been proposed[80], also transposition design has been done using a genetic algorithm
[73, 79]. Analysis of disc type transformer windings is not available.

6. Analysis of Electromagnetic Forces, Field Distribution, and Design

6.1 Electromagnetic Forces

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International Conference on Future of Engineering Systems and Technologies IOP Publishing
Journal of Physics: Conference Series 1478 (2020) 012029 doi:10.1088/1742-6596/1478/1/012029

Leakage flux density (B) and current interact to produce electromagnetic forces of a very large
magnitude. The leakage flux density is resolved by radial direction (Br) and axial direction (Ba). With
the current density, the action of radial leakage flux results in axial forces (Fa) and the axial leakage
flux density results in radial force (Fr). The forces and flux density in the HV winding of a transformer
are shown in figure 2. To study the deformation action on transformer winding the values of axial
forces and radial forces are used. In a power transformer, the analysis of electromagnetic field
distribution is based on electromagnetic theory [81], the eddy current losses are obtained [23, 82],
electromagnetic forces were investigated over the windings and inside the operating transformer using
FEM [8, 42]. By the method of finite element analysis, the electromagnetic forces have been
evaluated. The effect of tappings on transformer symmetry has been analyzed [82, 83]. The FEM
successfully computes the electromagnetic forces in low-frequency devices.

6.2 Short Circuit Forces and Design

In the power lines, the different phase comes in contact with each other, then a large current flow in
the circuit. The effect of impedance in the circuit may reduce the short circuit current as of the current
rises in the circuit. Because of the short circuit current, equipment will overheat and the production of
forces of the electrodynamic interaction may destroy the equipment. During the short circuit current,
the transient phenomenon observed because of current undergoes a continuous change.

Figure 2: Direction of radial and axial forces and flux density in HV winding of a Transformer
In the transformer windings during the short circuit, a large magnitude of current flows. When a
transformer is submitted to a short circuit condition the electromagnetic forces that arise in the
transformer are exerted on the windings. Figure 3 shows the short circuit current and forces in the
transformer winding. The short circuit current has a steady-state alternating component at fundamental
the frequency and an exponentially decaying current. The force experienced by a winding is
proportional to the square of the short circuit current. The force has four components, there are two
alternating components and two unidirectional currents. One of alternating component is at the
fundamental frequency, and the other at double the fundamental frequency, the double frequency
component of current is of a constant but smaller value. The other two components of force are
unidirectional; one is constant and the other is decreasing with time. With a fully offset current, the
fundamental frequency component of force is dominant during the initial cycles.
FEM has been used to analyze electromagnetic forces [5, 8, 11, 27, 53, 54, 76, 80, 82-84]. 3D FEM
analysis of electromagnetic forces in the transformer winding is compared with that done by numerical
analysis. The calculated values of the axial and radial force of the transformer by 3D FEM are
comparable with the numerical values [5].

Figure 3: Short circuit current and forces

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International Conference on Future of Engineering Systems and Technologies IOP Publishing
Journal of Physics: Conference Series 1478 (2020) 012029 doi:10.1088/1742-6596/1478/1/012029

50MVA one-phase transformer subjected to inflow (inrush) current was analyzed by FEM to
investigate electromagnetic forces at the time of faults [8]. FEM has been used to analyze the short-
circuit current in transformers [83-90]. Force calculated in power transformer along the HV and LV
winding defined with the help of FEM and this approach helped in the designing process [11]. The
asymmetrical form of excitation and the effect of some of the factors were calculated in 10MVA power
transformer 2D model developed and short circuit forces over distinct transformer parts were computed
[27]. In a distribution transformer effect of harmonics caused by non-linear load was analyzed. It was
used to separate the no-load hysteresis loss and no-load eddy current loss. The two-frequency method
was applied and it was observed that the core loss increases with an increase in applied voltage [53].In
a 360 MVA power transformer, the computation of 3D FEM was used for the evaluation of eddy
current fields. In this case the tank wall with a magnetic shunt, aluminum screen was analyzed [75].
By using FEM, the design of the window of transformer and magnetically built vector potential was
evaluated. The axial and radial FEM's were evaluated on the coil of the transformer and the
asymmetrical form of windings effect was analyzed [80]. To calculate the value of radial and axial
force the FEM method is used [85]. FEA method used to calculate resolving the forces exerted on the
coil of the single-phase shell-type distribution transformer [83]. During short circuit condition, Short
circuit forces have been computed for a different type of transformers dry type transformer [9], 3-phase
transformer [84] and transformer under load [86]. Calculation and comparison of Short circuit forces
in power transformer has been undertaken and the forces are calculated by 3 D FEM [2, 38]. The effect
of inrush current on electromagnetic forces has also been assessed [55]. Voltage harmonics have been
analyzed [53]. Performance analysis has been carried out for the dry type transformer [9]. The
deformation of windings due to electromagnetic forces has been analyzed [9] winding asymmetries
have also been analyses using FEM [5,87]. Winding height has been optimized for the least stresses
[53]. Transposing of the winding for design improvement has been undertaken [13, 40, 79, 80]. 3D
FEM has been used to study shielding [6,33], and insulation design [40]. The short circuit forces
produced during inter-turn faults have been evaluated [88]. Based on the forces the mechanical
characters of the transformer have been analyzed [89]. Extensive work has been done regarding
electromagnetic forces, winding design, evaluation of losses, however, the complete comprehensive
analysis of a designed transformer is not available.
Assessment of use of FEM for computation of losses, and electromagnetic forces during short-circuit
conditions in the publications referred to in this work are given in table 1.

Table 1.: Assessment of the use of FEM

Parameter assessed Total number of Publications Last publication
Year Number
Copper Loss 16 2017 4
Eddy Current loss 15 2016 1
Stray Loss 17 2017 2
Short circuit Forces 25 2019 4
The finite element method has gained popularity for the assessment of short circuit forces in
transformers in the current year.

7. Conclusion
A review of published work for the analysis of the different loss and electromagnetic forces in
transformers found that 2D and 3D FEM, integral equation method (IEM) and boundary element
method (BEM) have been used. The results of 2D and 3D FEM have been found to match with
analytical values. The 3D FEM for transformer performance under normal and fault conditions, for
different types of transformers, ratings, and design has found extensive popularity in the recent past.
FEM is a reliable method for analysis of losses, transposition, control, and elimination of hot-spot in
the transformer. Much work has been done on power transformer short-circuit withstand capacity and
losses that occur in different parts of transformers. Analysis of transposing of windings has been done.
Helical windings have been analyzed. It is found that there is scope for analyzing forces, and losses in
transformers having disc-type windings using FEM. There is no work available on the disc type

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International Conference on Future of Engineering Systems and Technologies IOP Publishing
Journal of Physics: Conference Series 1478 (2020) 012029 doi:10.1088/1742-6596/1478/1/012029

windings. The analysis of short circuit forces and losses due to the field created by disc type windings
that find much use in power transformers.

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