Maurice Iacoviello

ABB Scheron SA

European Club Flux 99

Presentation of ABB Scheron Use of Flux2-3D at ABB Scheron Presentation of a traction transformer Flux3D model related to a traction transformer Electrical characteristics of a traction transformer Conclusion Questions
Maurice Iacoviello

ABB Scheron SA

The company

ABB Scheron SA

Transformers division
Maurice Iacoviello

Medium voltage division

ABB Scheron SA

Medium voltage products

Maurice Iacoviello

ABB Scheron SA

Transformers products

First cting ondu of c r e Sup former ) trans rld (HTS o the w

Maurice Iacoviello

ABB Scheron SA

Traction transformer market

of th % 0 0 1 rket a m s s e Swi

World wide market

75 % 25 %

Centre of excellence for traction transformer within ABB Group

Maurice Iacoviello

ABB Scheron SA

Use of Flux2-3D at ABB Scheron

Short circuit impedance calculations (SCI) Determination of additional losses due to Eddy currents (tank, hardware material, ...) Temperature rise calculation Electrical field calculation

Maurice Iacoviello

ABB Scheron SA

Presentation of a traction transformer ICN transformer

INTER CITY NEIGEZUG

2260 kVA Underframe 15 kV; 16 2/3Hz 2 tractions windings Aluminium tank Mineral oil Class A

Maurice Iacoviello

ABB Scheron SA

Why use Flux3D instead of a traditional design software

To optimise electrical parameters like SHORT CIRCUIT IMPEDANCE TANK LOSSES We have modelised the transformer in order to optimise these parameters!
Maurice Iacoviello

ABB Scheron SA

Evolution of the transformer design

1.Increase of the cover thickness 2.Increase of the tank height 3.Use of shunts 4.Use of different aluminium alloys 5.ICN final version
Maurice Iacoviello

ABB Scheron SA

ICN model design under Flux3D

Description of volume regions Description of surface regions Description of used material Description of windings Meshing Type of resolutions Exploitation of results
Maurice Iacoviello

ABB Scheron SA

Description of 3D regions
Magnetic circuit Formulation scalar total MD3SCA

Fictive air gap

Used to eliminate connexity problems

Formulation scalar reduce MD3RED

Maurice Iacoviello

Infinity and air Formulation scalar reduce MD3RED

ABB Scheron SA

Description of 3D regions
shunts Magnetic lation Formu tential vector po electrical MD3AV

Description of windings
Formulation sc alar total
Fictive pres Nothing me entation shing N* Phase angle

Inductors

Maurice Iacoviello

ABB Scheron SA

Description of surface regions

Advantages of these regions
Keep thin regions in account with a light description Use of shell elements No volume meshing needed Smaller file Quicker resolution

Maurice Iacoviello

ABB Scheron SA

Description of surfacic regions

Cover and tank shell elements Formulation pot.red.general double MD3CGR

Copper shunts shell elements Formulation pot.red.general double MD3CGR

Maurice Iacoviello

ABB Scheron SA

Meshing
Regulate meshing Surface regions Check of number and quality of elements

Maurice Iacoviello

ABB Scheron SA

Meshing
Volume meshing
Have 2 3 fine elements inside of skin thickness Volume shunts

In general a good meshing should not have more than 5% bad elements

Type of resolutions
linear magnetodynamic Tank without magnetic shunts

No linear magnetodynamic Tank with magnetic shunts

Maurice Iacoviello

ABB Scheron SA

Exploitation of results
Tank losses with FLUX3D
PCOQ2 allows to determine the tank losses

Short circuit voltage with Flux3D

With volume and surface energy

Visualisation of Eddy current in the tank and in shunts Visualisation of flux density in the magnetic shunts Visualisation of main flux in the magnetic circuit Visualisation of magnetic radial fields in the disc windings
Maurice Iacoviello

ABB Scheron SA

Tank losses and magnetic shunts

Tank losses
Average surface power density. complex Real part of PCOQ2, give the losses
Tank
losses

Magnetic shunt losses

Losses
Mag _ shunts

dv

[W ]

The factor 1/2 is due to the use of peak values

Surf

= REAL (

PCOQ

2)

[W ]
1 2

Losses

Mag _ shunts

dv

[W ]

Maurice Iacoviello

ABB Scheron SA

Determination of SCI
Volume energy is calculated with FLUX 3D with this relation.
E vol =

1 conj ( BMAG 2 ) ( HMAG 2 ) dV [ J ] 4

Total energy :

Surface energy in shell elements is given by :

Losses =
Surf

E = E vol + E surf [ J ]
Short circuit impedance :

PCOQ

2 ds

[W ]

Real PCOQ2 = Eddy losses Im (PCOQ2) = Reactive energy

E surf = Im {PCOQ 2 4 f

Lcc =

4 E
2

[H ]

}[ J ]

Maurice Iacoviello

ABB Scheron SA

Visualisation of Eddy current

Density of surfac e current in the ta n k and the shunts Perm it to loca te hot spot s on the tank and current loops

Maurice Iacoviello

ABB Scheron SA

Visualisation of the SCI

Shunts saturation
Non linear simulation

Visualisation of the main induction magnetic circuit

Core flux density

Maurice Iacoviello

ABB Scheron SA

Magnetic fields

We can observe the radial flux hitting the tank

Maurice Iacoviello

ABB Scheron SA

Evolution of the transformer design

1. Increase of the cover thickness 2. Increase of the tank height 3. Use of shunts 4. Final version

Maurice Iacoviello

ABB Scheron SA

Increase of the cover thickness

A, B, C fixed

We have compared different cover thickness

fixed

0.9 FLUX3D measured 0.8

0.7 A B Thickness C

10 9 8 7 6 5 4 3 2 1 0

Error [%]

Losses [%]

Maurice Iacoviello

ABB Scheron SA

Increase of the tank height

fixed A, B, C

We have compared tank height for additional frame.

Cover thickness constant
A, B, C

1 Losses [%]

5.6 5.4 5.2

Error [%]

0.9 Flux3D Measured

5 4.8 4.6 4.4 4.2

0.8

0.7 A B Tank height C

Maurice Iacoviello

ABB Scheron SA

Use of magnetic and copper shunts

SHUNTS
fixed fixed

We have add shunts under the cover and in the bottom of the tank
Aluminium cover and tank Magnetic shunts or copper shunts
1 0.9 Losses [%] 0.8 0.7 0.6 0.5
ucc [%]
fixed

Flux3D Measured

Flux3D Mesured Client

Magn

etic

er Cop p

Type of shunts

Mag

netic

Cop

pe r

Type of shunts

Maurice Iacoviello

ABB Scheron SA

FINAL VERSION Modifications

Losses [%] 1 0.75 0.375 Flux3D Measures

Design update
choose of low loss aluminium alloys Increase of cover-winding distance Fine tuning of the active part

0 ICN FINAL

Final

Final

ucc [%]

Flux3D Measures Client

Final

ICN FINAL

Maurice Iacoviello

ABB Scheron SA

CONCLUSION
Comment about the results
The infrared picture demonstrate that the hot points are following the current distribution calculated with Flux3D.

Remark :
With help of Flux3D the final target could be reached very fast !

Maurice Iacoviello

ABB Scheron SA

CONCLUSION

Positive points of Flux3D

Decrease of fabrication costs Results conform to reality Anticipation of potential problems Powerful tool Precision of calculation

Maurice Iacoviello

ABB Scheron SA