Single Phase Transformer

How Does a Single Phase Transformer Work?

A single phase transformer works based on Faraday’s law of electromagnetic induction. When alternating current is applied to the primary winding of a transformer, alternating magnetic flux is generated. The magnetic flux couples with the secondary winding and generates an induced electromotive force.

Based on the principle, ZHONGSHAO single phase transformers improve the efficiency of this process to 98% by improving material quality and optimising the core structure.

Core Parts of Single Phase Transformer

Winding

Windings are coils wound on an iron core and are divided into primary and secondary windings. They are the most important part of a single phase transformer.

The wire specifications and insulation performance of the windings must meet the requirements to ensure that the windings have electrical strength.

The materials for windings should have good heat resistance to avoid winding damage caused by excessive current during operation.

Long-term electromagnetic force can easily cause deformation of the windings, so the windings should possess sufficient mechanical strength.

Long-term operation at high temperatures will accelerate the windings’ aging, so the operating temperature of the windings should be kept within a suitable range. Also, poor heat dissipation can lead to localized overheating, increasing copper losses.

Magnetic Core

A magnetic core forms a closed magnetic circuit and supports winding. Usually, it is made of iron or steel and has good magnetic performance and mechanical strength.

It transforms the electrical energy of the primary winding into magnetic energy and guides magnetic flux from the primary winding to the secondary winding.

The quality and structure of the magnetic core directly determine the no-load loss of the transformer. Modern magnetic core adopts a stacked structure, which can reduce the generation of eddies, thus avoiding the generation of heat in the magnetic core and wasting some electrical energy.

Insulating Materials

Insulating materials used for single phase transformers include glass, mica, insulating varnish, etc. Our insulation materials have an insulation class of F and above, which have a longer service life in high-temperature environments and prevent short circuits.

Insulating varnish is often used in the stacks in the magnetic core, which can significantly increase the winding’s resistance and reduce eddy current generation. Sometimes the surface of the magnetic core is covered with a thin oxide film, which has an insulating effect and doesn’t need to be coated with insulating varnish.

Types of Single Phase Transformer

Single phase transformers can be classified into core-type transformers, shell-type transformers, and autotransformers based on the layout of the windings and magnetic core.

Core-type Transformers

The primary and secondary windings of a core-type transformer are arranged on the central column of the magnetic core. It has a higher magnetic coupling efficiency than a shell-type transformer.

Shell-type Transformers

The windings of a shell-type transformer are in the magnetic core, and they are surrounded by the magnetic core. Therefore, the leakage flux of a shell-type transformer is very small, and its magnetic density is very high.

The enclosed winding structure protects the magnetic core, so it is particularly suitable for circuits requiring high short-circuit strength and industrial environments with high durability requirements.

Autotransformer

The primary and secondary windings of an autotransformer have overlapping sections. It is one of the few single phase transformers that are capable of handling complex circuits.

Advantages of Single Phase Transformer

Small Occupied Spaces

For small and medium-sized factories that need to strictly control space to save costs, our single phase transformers have a compact structure, saving you space costs. They can be installed even in very compact server racks.

This structure is convenient for us to manage inventory and effectively addresses your urgent restocking needs.

High Efficiency

The stacked magnetic core reduces eddy current losses, achieving a magnetic core utilisation rate of up to 98%, helping you save thousands of yuan in electricity costs each year. For equipment with long operating times or high power consumption, our single phase transformers can significantly reduce electricity costs.

ZHONGSHAO, as a transformer manufacturer with 20 years of experience, has extensive expertise in energy-saving solutions for transformers.

Safety

Compared to the complex operating system of a three phase transformer, a single phase transformer has a simpler structure and can maintain voltage more stably.

Before the transformer leaves the factory, we conduct rigorous factory tests, such as temperature, pressure, and sudden short-circuit tests, to protect your electrical equipment from the effects of unstable voltage.

Applications

Home Appliances

Single phase transformers reduce the high-voltage electricity from power plants to 120V and 240V to suit household appliances such as television voltage regulation, lighting, and heating equipment.

If you are a home appliance manufacturer, your appliances need to operate safely and stably. ZHONGSHAO single phase transformers are overload-resistant, ensuring the safe operation of your appliances and reducing customer complaints.

Remote Rural Areas

remote rural areas usually have low electricity demand and unstable power supply voltage. If you need to supply power to remote areas, you need to pay special attention to the unstable voltage. ZHONGSHAO single phase transformers can handle voltage fluctuations very well, ensuring a stable voltage delivered to residents’ homes and reducing safety hazards.

Small Business Applications

The lighting systems, refrigeration equipment, heating equipment, and other electrical systems of restaurants and retail stores require a stable voltage for their operation. Flashing lights directly impact the consumer experience, while downtime of refrigeration equipment can lead to food loss.

Office equipment in small businesses requires a stable voltage to avoid the risk of data loss and enhance business efficiency. Stable transformers help these small business owners achieve business continuity.

Small Industrial Environment

Single phase transformers are commonly used in assembly lines, CNC machine tools, small water pumps, and other low-power equipment.

Dust, high temperatures, and humidity in industrial workshops can easily lead to power system faults and cause voltage deviations. Voltage fluctuations can lead to decreased equipment efficiency. Excessive voltage can burn out electronic components, while insufficient voltage can’t provide enough power to start.

The high-temperature resistant windings and a fully enclosed casing of ZHONGSHAO single phase transformers can effectively isolate dust and water vapour, reducing your equipment’s maintenance costs.

How to Select a Suitable Single-Phase Transformer?

Types of Application Device

Equipments of different types have different load types, including resistive load, inductive load, and nonlinear load.

Equipment with inductive loads, such as compressors, reduces the power utilisation of transformers, so it requires transformers that can handle higher power.

Equipment with non-linear loads, such as rectifiers and frequency converters, is prone to producing harmonics, which can cause localised overheating of the transformer. So, it is suitable for transformers with strong harmonic rejection capabilities.

Application Environment

Environmental factors affecting transformers include temperature, humidity, and cleanliness. For example, the maximum temperature of your application environment directly determines the insulation class of the transformer you choose. Insulation materials of different classes have different maximum temperature tolerances.

If your installation environment is full of dust and splashing liquids, the transformer enclosure needs to be selected with different protection levels depending on the environment, like IP45/IP55.

Voltage Rating

The voltage rating of a single phase transformer determines the input voltage, thus affecting the output voltage. When the input voltage fluctuates, the single phase transformer needs to maintain a stable output voltage to ensure the normal operation of the equipment.

Power Rating

Power rating refers to the maximum power that a transformer can safely withstand during normal operation. The power rating needs to be compatible with the power supply and generator capacity of your equipment.

Magnetic Core Loss and Copper Loss

During operation, the magnetic core continuously magnetises and demagnetises, and the windings generate heat when current flows, causing copper losses. Single phase transformers should be made of high-quality materials during manufacturing to reduce losses and improve efficiency.