From Spreadsheets to Multiphysics Applications, ABB Continues to Power Up the Transformer Industry

Companies developing new and improved power transformer equipment incur costs for prototyping and testing as they work to reduce transformer hum. At ABB, a team of engineers develops multiphysics simulations and custom-built applications to offer insight into their designs. Transformer noise often comes from several sources, such as vibrations in the transformer core or auxiliary fans and pumps used in the cooling system. Each of these sources needs to be addressed differently to reduce noise. ABB’s transformers comprise a metal core with coils of wire wound around different sections, an enclosure or tank to protect these components, and an insulating oil inside the tank. Passing alternating current through the windings of one coil creates a magnetic flux that induces current in an adjacent coil. The voltage adjustment is achieved through different numbers of coil turns. Because the core is made of steel, a magnetostrictive material, these magnetic fluxes — which alternate direction — cause mechanical strains. This generates vibrations from the quick growing and shrinking of the metal. These vibrations travel to the tank walls through the oil and the clamping points that hold the inner core in place, creating an audible hum known as core noise. In addition to the core noise, the alternating current in the coil produces Lorentz forces in the individual windings, causing vibrations known as load noise that add to the mechanical energy transferred to the tank.

ABB is one of the biggest manufacturers of transformers used around the world, headquartered in Zürich, Switzerland. The company is renowned for its expertise in power and automation technologies, providing solutions for a wide range of industries including utilities, industry, transport, and infrastructure. ABB’s transformers are integral to the electrical grid, which powers buildings like homes, businesses, and schools. The company’s transformers are used to increase and decrease voltage levels in power lines that carry alternating current, ensuring efficient and safe power transmission over long distances. ABB’s commitment to innovation and quality has led them to use advanced numerical analyses and computational applications to predict and minimize noise levels in their transformers, ensuring compliance with safety regulations and enhancing customer satisfaction.