Transformer Design Challenges and Simulation Requirements
📌 Three-phase power transformers are crucial components requiring high efficiency, precision, and long operational life in energy distribution networks.
⚙️ Key design issues requiring simulation include calculating magnetic fields, evaluating saturation levels, testing winding configurations ($\text{delta}$ and $\text{star}$), and determining $\text{AC}$ and $\text{DC}$ resistances/inductances.
📉 Mandatory pre-building analysis includes no-load conditions to extract the equivalent circuit and short-circuit analysis to evaluate high currents and damage risks to the system.
🔥 Critical evaluations involve accurately estimating losses (to reduce heat), predicting temperature and structural deformation, and investigating electric fields to limit insulation breakdown voltages.

EMWorks Simulation Solution Overview
🤖 EMWorks offers an electromagnetic simulation package supporting both 2D (faster iterations for early design stages) and 3D analysis (final validation incorporating 3D phenomena).
🔗 The solution integrates an circuit simulator using linear/non-linear components (resistors, inductors, switches) to model transformer circuits.
🌡️ Multiphysics options allow seamless, coupled analysis—such as magnetic, thermal, and structural—within a single study without data export/import.
🛠️ The package includes the Transformer Wizard, a template-based $\text{CAD}$ design tool for automatically generating 3D geometries for single-phase and three-phase transformers, integrated within $\text{SolidWorks}$ and $\text{Autodesk Inventor}$.

Simulation Case Study: $\text{Y-Y}$ vs. $\text{Delta-Star}$ Connections
⏱️ A transient magnetic solution was performed using EMWorks 2D, first analyzing open-circuit conditions ($\text{Y-Y}$ connection, $1\text{ kV}$ input, $50\text{ Hz}$) to visualize magnetic field distribution versus time.
⚡ Short-circuit tests revealed higher short-circuit currents and associated winding losses ($\approx 17\text{ kW}$) compared to the $\text{Y-Y}$ connection when using the delta connection ($\approx 50\text{ kW}$ losses).
🌡️ Steady-state magnetic analysis using 3D allowed for coupled electro-thermal-structural studies to identify temperature hot spots and structural deformations caused by magnetic forces and thermal stress.
⚡ Dielectric failure investigation used electric field analysis; a calculated safety factor compared the electric field against insulation dielectric strength, where a factor $>1$ indicated a breakdown risk.

Transformer Wizard and Software Demonstration
📐 The Transformer Wizard, integrated into $\text{SolidWorks}$, automatically generates 3D geometry templates based on user-defined core and bobbin parameters.
🔄 The $\text{EMS}$ (3D) and $\text{EMWorks 2D}$ environments support various magnetic studies: magnetostatic, $\text{AC}$ magnetic, and transient magnetic.
🔄 The software allows parameterization of both geometric variables (e.g., core diameter) and simulation variables (e.g., current, voltage), and supports $\text{SolidWorks}$ multi-configuration to compare several design iterations within one model.
📚 The material library includes well-organized linear and non-linear magnetic materials, allowing customization and automatic $\text{B-H}$ curve generation based on initial permeability and saturation points.

Key Points & Insights
➡️ Virtual prototyping via simulation is crucial to save money, effort, and time in transformer design, given the high cost of physical prototypes.
➡️ Utilize coupled multiphysics analysis ($\text{Magnetic} + \text{Thermal} + \text{Structural}$) within a single study to understand complex interactions like heat generation causing deformation.
➡️ Employ 2D simplification early in the design process for faster iteration cycles, reserving 3D simulation for final validation of results.
➡️ Analyze the safety factor in dielectric studies ($\text{Electric Field} / \text{Dielectric Strength}$) to automatically quantify the risk of insulation breakdown ($\text{Safety Factor} > 1$).

📸 Video summarized with SummaryTube.com on Nov 10, 2025, 13:29 UTC