Transformer Design Analysis

Trafoexperts Transformer Consulting Services

With the software and hardware tools available today, it is possible to verify the performance of a transformer before building it.

An example is the 3D simulation of stray losses and temperature distribution on a rectifier transformer for aluminium smelters with an 80kA LV current. This simulation verifies the presence of tank hot spots. Such hot spots may deteriorate the gaskets of the tank cover or the busbars, causing oil leakage. The transformer would then need to be taken out of service. The direct and indirect costs of such a transformer outage are order of magnitudes higher than the cost of a transformer design analysis.

However, running these advanced simulations needs skill, time, and high-performance tools.


Our consulting service

With our experience and our simulation tools (both Infolytica software and tools developed by us), our transformer consultants can perform very advanced design analyses. 

partial list of our design analysis service is given below. If what you need is not listed, then please contact us and we may be able to support you.

  • HVDC and UHV AC
  • Generator step up
  • Electric arc furnace
  • Rectifier
  • Statcom
  • Cycloconverter
  • Voltage regulation
  • Power electronics
  • Shunt
  • Series
  • Saturable reactors (for DC voltage regulation with diode rectifiers)
2D and 3D Analyses

Insulation systems

  • AC and DC (with transient)

Load loss, circulating currents and hot spot

  • Windings (with harmonics)

Stray losses and temperature

  • Tank
  • Clamping structures
  • Flitch plates


  • Short circuit / zero sequence

Electromagnetic forces

  • Short circuit
  • During inrush (with 1 and 2 cores)
Active part with ...
  • extended delta windings
  • zig-zag windings
  • multiple coils in parallel
  • foil windings
  • 3D tap leads
  • magnetic shunts
  • Cu/Al flux shields
  • single and double cores
  • gapped core
  • frame core
  • coreless coils
Dr. Ing. Ugo Piovan

Dr. Ing. Ugo Piovan

Transformer Consultant
Trafoexperts GmbH

Turbinenweg, 4
8610, Uster, Switzerland