Magnetic Flux and Core Loss Finite Element

Analysis of Electrical Steels Combinations in

Lamination Core Steps of Single-Phase Distribution
Transformers
Salvador Magdaleno-Adame1, Sudheer Mokkapaty2, Themistoklis D. Kefalas3
1
Salvador Consultant, Michoacan, 59377, Mexico, e-mail: salvador.consultant@scryptmail.com
2
SGB Transformers, Neumark, 08496, Germany, e-mail: mokkapatysudheer.eee@gmail.com
3
Hellenic Electricity Distribution Network Operator HEDNO S.A, Athens, 10434, Greece, e-mail: t.kefalas@deddie.gr

Abstract—This paper presents a finite element (FE) analysis current transformers to reduce material costs and to improve
of combinations of electrical steels in the lamination core steps of their measurement properties [11]-[15]. Finally, some authors
a real 6.3 MVA single-phase distribution transformer. The have combined GOESs and amorphous steels in magnetic
magnetic core of this transformer has a cruciform cross-section cores of distribution transformers to reduce losses and material
with lamination core steps. Two electrical steels are combined in costs [16].
the lamination core steps of transformer: a convectional grain
oriented electrical steel (M-5) and laser-scribed electrical steel Furthermore, after reviewing the existing literature, the
(23ZDKH90). 3-D FE simulations are performed to calculate the authors note that there is not information related with
core losses (no-load losses) without and with combinations of combinations of GOESs in the lamination core steps of
electrical steels. B-H curves and iron loss curves of electrical distribution transformers. J.C. Granfield in 1949 proposed to
steels are taken into account in the numerical simulations. The combine GOESs and NGOESs in lamination core steps in
core loss calculated in FE simulation without combination of stacked magnetic cores of transformers, inductors, and reactors,
steels is compared with the core loss measured in no-load see Fig. 1 [1]. He proposed to use GOES laminations in the
laboratory tests. Results obtained in this paper show that the internal core steps and NGOES laminations in the outer core
combination of electrical steels in the lamination core steps can steps to reduce power losses [1]. In this paper the idea of J.C.
reduce 5% the core losses in single-phase distribution Granfield is utilized but considering only GOESs with different
transformers with stacked magnetic cores. magnetization and iron loss (W/kg) properties in the core steps
of a distribution transformer.
Keywords—core loss; distribution transformer; electrical steel;
no-load loss; finite element; lamination core step

I. INTRODUCTION
The combinations of electrical steels in magnetic cores of
transformers are employed by manufacturers to reduce losses,
temperature, and costs [1]-[16]. Actually in USA, Mexico,
Greece, Germany, Italy, Japan, and Poland some transformer
companies are combining electrical steels and high
permeability alloys in magnetic cores of transformers.
Furthermore, in the last twenty years, the combinations of
electrical steels and ferromagnetic materials have been studied
and applied in instrument, power, and distribution transformers
and new core transformer topologies have been proposed to
combine electrical steels in distribution and power transformers
[1]-[16]. Some authors have analyzed the combination of grain
oriented electrical steels (GOESs) in magnetic cores of
distribution and power transformers to reduce core losses, Fig. 1. Granfield’s idea to combine grain oriented steel (hot rolled steel) and
temperature, manufacturing costs, and material costs [2]-[4]. non-grain oriented steel (cold rolled steel) in lamination core steps of a
magnetic core [1]. Extracted from patent US 2 465 798, 1949.
Other authors have analyzed combinations of GOESs in
magnetic wound cores of distribution transformers to reduce This paper presents a magnetic flux and core loss numerical
losses [5]-[10]. Other authors have combined GOESs and non- analysis of combinations of electrical steels in a magnetic core
grain oriented electrical steels (NGOESs) in instrument of a real 6.3 MVA single-phase distribution transformer. The
transformers, and other authors have combined GOESs and magnetic core of this transformer has a cruciform cross-section.
some high permeability alloys in toroidal magnetic cores for A convectional GOES (M-5) and a laser-scribed electrical steel
(LSES) (23ZDKH90) are combined in the lamination core TABLE I.
steps of transformer. 3-D finite element (FE) simulations are TECHNICAL CHARACTERISTICS OF DISTRIBUTION TRANSFORMER
performed to compute the core losses and magnetic flux No. phases 1
distributions in the transformer magnetic core with and without Frequency 50 Hz
combinations of electrical steels. Furthermore, the core loss of Impedance 7.83%
transformer without combinations of electrical steels is Transformer rating 6.3 MVA
measured in laboratory and compared with FE simulation. High voltage (HV) winding 10.5 kV
With this comparison, authors validate the FE simulations in Low voltage (LV) winding 710 V
this paper. The magnetization properties and iron loss
properties of electrical steels are taken into account in the
nonlinear FE simulations. B. Magnetic Core Modeling
The original and real magnetic core of the transformer is
II. 3-D FINITE ELEMENT SIMULATIONS
built using the step-lap overlap technique. In the 3-D FE
The distribution transformer is modeled in three dimensions simulations the ‘45°’ overlap core joints are not taken into
(3-D). ANSYS Maxwell software is utilized to compute the account in this paper. To reduce the computational complexity
losses in the magnetic core with and without combination of inter-laminar layers are avoided and only the solid lamination
electrical steels [17]. steps are considered in the FE simulations.
A quasi-static magnetic vector potential formulation is The real magnetic core is made of laminations of M-5
utilized to solve 3-D eddy current problems given by: electrical steel [18]. This is a convectional GOES utilized in
1  the manufacturing of distribution transformers. The M-5 steel
∇ ×  (∇ × A)  = J e − jωσ A (1) laminations have a thickness of 0.30 mm, a mass density of
µ  7650 kg/m3, and an electrical conductivity of 1.96×106 S/m.
where µ is the permeability (H/m), A is the magnetic vector Furthermore, 23ZDKH90 steel is a GOES treated using the
potential (Wb/m), Je is the current density (A/m2), ω is the laser scribing method [19], [20]. The laser scribing process
angular frequency (rad/s), and σ is the electrical conductivity refines the magnetic domains, increases the magnetic
(S/m). The finite element method (FEM) is utilized to solve permeability, and reduces the losses in the steel [20]. The
equation (1) in the domain of transformer model. 23ZDKH90 steel laminations have a thickness of 0.23 mm, a
mass density of 7650 kg/m3, and an electrical conductivity of
2×106 S/m [19]. In the distribution transformer the electrical
A. Exciting Windings Modeling steels M-5 and 23ZDKH90 are combined in the twenty
For 6.3 MVA single-phase distribution transformer only the lamination core steps of transformer. Fig. 3 shows a view of
low voltage (LV) winding is used to magnetize the core of the lamination core steps of the cruciform cross-section of
transformer, the high voltage (HV) winding is omitted in order distribution transformer.
to provide open circuit test conditions. The exciting winding is The experimental B-H curve and the specific iron loss
made of aluminum with a relative permeability of 1 and an curve of M-5 and 23ZDKH90 steel at 50 Hz are used in the FE
electrical conductivity of 3.8×107 S/m. The excitation winding simulations [18], [19]. These curves are obtained from the
has 18 turns. The power losses produced in the excitation steel manufacturers using an Epstein frame. Fig. 4 shows the
winding are omitted. Fig. 2 shows the 3-D distribution specific iron loss curves for M-5 and 23ZDKH90 steel at 50
transformer model and Table I shows the technical Hz. The magnetic core of distribution transformer is designed
specifications of distribution transformer. to operate at 1.63 T.
C. Core Losses in Distribution Transformer
The core losses in the distribution transformer are computed
by ANSYS Maxwell software utilizing a numerical dynamic
core loss model (DCLM) [21]. Utilizing this core loss
numerical model one avoids the use of very small finite
elements in the magnetic core models of transformers or
electrical machines [21]. A hysteresis loss coefficient (kh) and
an eddy current loss coefficient (kc) are used to compute the
total core losses in magnetic cores of transformers. DCLM
uses the magnetic field distributions and the loss coefficients
to compute the losses in the core of distribution transformer
with and without combinations of steels. DCLM utilizes
equivalent elliptical loops to simulate the hysteresis cycles in
the core of transformer and electrical machines [21]. Utilizing
Fig. 2. 3-D model of magnetic core of 6.3 MVA distribution these hysteresis loops ANSYS Maxwell can calculate the
transformer. hysteresis losses in the core of distribution transformer [21].
Furthermore, kc coefficient is given by [21]:
 Fig. 3. View of cruciform cross-section and lamination core steps of
magnetic core of distribution transformer.

Fig. 5. Finite element mesh of distribution transformer.

E. Nonlinear Time-Harmonic Analyses

Nonlinear time-harmonic analyses are carried out to
compute the core losses in the transformer core. An exciting
current Iexc = 8.3 A at 50 Hz is injected in the LV winding to
magnetize the magnetic core. The excitation current of this
transformer is measured in laboratory during the no-load test
Fig. 4. Experimental specific iron loss curves for M-5 and 23ZDKH90 and corresponds to 0.1% of the nominal current of
steel at 50 Hz [18], [19]. transformer.
π 2σ s d s2 F. Core Losses in Magnetic Core without Combination of
kc = (2) Electrical Steels
6
where ds is the thickness of electrical steel laminations and σs Fig. 6 shows the magnetic flux density distributions for core
is the electrical conductivity of electrical steel laminations. of distribution transformer without combinations of electrical
steels.
The loss coefficients kh and kc for electrical steels in the
magnetic core of the transformer are computed by ANSYS
Maxwell software utilizing a regression method, the specific
iron loss curves of electrical steels, and properties of electrical
steels.
Table II shows the hysteresis and eddy loss coefficients for
M-5 and 23ZDKH90 steel at 50 Hz computed by ANSYS
Maxwell software.

TABLE II.
LOSS COEFFICIENTS UTILIZED TO COMPUTE CORE LOSSES IN MAGNETIC
CORE OF DISTRIBUTION TRANSFORMER
Loss M-5 23ZDKH90
Coefficient (50 Hz) (50 Hz)
kh 51.92 43.26
kc 0.29 0.17

D. Finite Element Mesh of Transformer

A total of 113,000 finite elements are used in the Fig. 6. Magnetic flux density distribution in magnetic core of transformer with
M-5 steel.
transformer model. Fig. 5 shows the FE mesh of the magnetic
core of the distribution transformer. Table III shows the core loss computed and measured for
distribution transformer without combinations of electrical
steels. A difference of 3.48% is calculated between the core
loss calculated in FE simulation and the core loss measured in magnetic flux density (Bavg) in the cruciform cross-section for
no-load test. each combination of steels. A value Bavg = 1.72 T is calculated
for the steel combinations. Moreover, a maximum flux density
TABLE III. of 1.805 T is calculated in the combined core in the core steps
CORE LOSS IN MAGNETIC CORE WITHOUT ELECTRICAL STEELS with 23ZDKH90 steel.
COMBINATIONS IN DISTRIBUTION TRANSFORMER
Core Loss Core Loss Loss TABLE IV.
(FE analysis) (Measured) difference CORE LOSSES AND LOSS DIFFERENCE OF ELECTRICAL STEEL COMBINATIONS
Total core IN DISTRIBUTION TRANSFORMER
4.15 kW 4.30 kW 3.48%
loss
Steel Core Loss Loss
Combination (kW) difference
A1 4.15 −
G. Core Losses in Magnetic Core with Combinations of A2 4.10 1.20%
Electrical Steels A3 4.03 2.89%
The combinations of electrical steels in lamination core A4 3.95 4.82%
steps of distribution transformer are shown in Fig. 7.

Fig. 8. Magnetic flux density distributions in lamination core steps.

Fig. 7. Electrical steel combinations in lamination core steps of transformer.

The larger volume of steel in the main and central core steps
contributes higher amount of losses. Hence, LSES is preferred
in the central steps and GOES is applied on the outer steps.
Figs. 8 and 9 show the magnetic flux density and core loss
distributions in the core steps of the distribution transformer for
the different combinations of steels. From these figures one
can see that the magnetic flux and loss distributions change
when one increases the amount of LSES in the core steps. The
increment of LSES in the inner core steps and the reduction of
GOES in the outer steps produce a reluctance change in the
magnetic core. One part of the magnetic flux prefers to
circulate in the inner core steps where the permeability is high
and the losses (W/kg) are smaller and another part of the
magnetic flux is forced to circulate in the outer core steps
where the permeability is lower and the losses (W/kg) are a
little higher. This imbalance of flux and losses produces a
reduction of the total core loss in the magnetic core of
distribution transformer. Fig. 9. Volumetric core loss distributions (W/m3) in lamination core steps.
Table IV shows the core losses calculated for the steel III. CONCLUSIONS
combinations in the magnetic core of distribution transformer.
This table includes the loss difference between the steel The magnetic field distributions and core losses in a
combinations in magnetic core and the magnetic core without magnetic core of a real single-phase distribution transformer
steel combinations. The authors calculated the average without and with combinations of electrical steels in the
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