The customer is a transformer manufacturer who wanted to design and manufacture a new transformer type for solar plants. Due not having the relevant expertise with the previous designs, they wanted to compute in a very detailed way, to find all losses in the transformer before manufacturing it.

Why APA Team?

APA has been designing and simulating transformers and electric devices during for past 25 years. Hundreds of engineers have been trained in magnetism, transformers and electric machines design.


To simulate a 6560 KVA transformer for renewable energy plants; both magnetic and electric field computation.

Geometry of the model


Design Challenges Involved:

● Detailed losses computation in windings, iron, flanges, connections and tank

● Certain computations may require a lot of computation time, and so, an equivalent 2D model was used for winding losses in order to compute them as accurately as possible.

Simulation Process:

● Simulation #1: Steady state magnetic AC simulation with FLUX3D to compute:

○ Losses in the magnetic circuit

○ Losses in bushings and connections

○ Losses in structural elements (flange, tank)

● Simulation #2: Steady state magnetic AC simulation with FLUX2D taking into account a detailed winding representation to compute and determine:

○ Losses in transformer’s winding

● Simulation #3: Electrostatic simulation with FLUX3D to obtain:

○ Electric field distribution in different parts of the geometry (windings, LV conections, etc.).

Losses density in LV and HV windings

Magnetic Flux Density

Value Delivered:

● Accurate way to compute losses according new regulations

● Cost reduction of prototypes and time to market

● Better understanding of product before manufacturing.

The author, Dr.Vicente Aucejo is an Electromagnetic simulation expert with more than 25 years of experience, drives APA's Global strategy for Electrical vehicle Engineering Solutions. He can be reached at [email protected].

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