Pole Mount Distribution Transformer Design

y,

It sounds like something I'd try and buy from someone who knew what they were doing. Why do you need to make it yourself?

George H.

Please tell me that this is a student project, and your design will never hang on the pole outside my house!

And folks wonder why we need licensed engineers.

Start with a good Electric Machines text, like "Electric Machines: Steady-State Theory and Dynamic Performance", M. S. Sarma, (C) William C Brown, 1986. It goes into the trade-offs between iron, iron sizes, wire, etc. Then get yourself a book that's _just_ about designing heavy-iron transformers.

The get yourself about five to ten years of experience in industry, helping to design these things, particularly in analyzing ones that have come back to the factory after incidents. Once you've spent some serious career time analyzing why the melt/burn/explode, then you'll be ready to set out and design one.

"slither"

You need: "alt. suicidal.lunatics "

... Phil

Sure sounds like a homework question.

pick some figures and run the math see how much you loose in resistive losses, eddy currents, and the like.

adjust the figures, repeat.

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y,

This is going to take some research into the economics. Your best core design depends on the relative cost of lost energy and the best specialty materials. You'll make a cost-amortization calculation.

The design of pole pig transformers includes cooling oil and enclosures, mechanical mount provisions, bird-tolerance, weather resistance, transient overvoltage and overload tolerance, etc.

Looking up steel formulations for the magnetic properties will only give you an idealized (fully-annealed unstressed) sample's properties, NOT the full as-manufactured performance of the finished product.

The stuff between windings is only PARTLY insulation; it's also mechanical stress relief.

Really designing one of these for mass-production is a daunting task. Have fun!

If you check a catalog or actually open such a transformer up you'll find

aluminum primary, aluminum secondary would from flat straps, a step-lap core and insulation made of transformer paper, probably epoxy cured and then the tank filled with oil for cooling and insulation.

some places might still use copper, but it costs more so utilities don't care for that.

distribution transformers are designed to be efficient and to not rip into pieces if they experience a fault. the magnemotive forces can be quite high in such large devices.