Our guide to electrical transformers

You don’t need to become an expert on electrical systems to run a manufacturing business, but understanding the basic components can be useful. When you understand how your system is made up, it can help you identify inefficiencies or determine the cause of a fault more easily.

Electrical transformers are a fundamental component in electrical power systems. They convert energy from one circuit to another using electromagnetic induction. They play a key role in voltage regulation and power distribution, improving efficiency and safety.

How do transformers work?

Transformers work on the principle of electromagnetic induction, which was discovered in the 1830s and enabled us to better understand and harness electricity.

Electromagnetic induction refers to the process in which a current-carrying conductor produces a magnetic field around it (and vice-versa). A transformer uses this process to convert electrical energy from one circuit to another, raising and lowering voltage levels as and when needed.

A transformer consists of two sets of wires, referred to as coils or windings. The primary and secondary windings are wound together on a magnetic circuit core, but they are not in contact with one another.

When an electrical current flows through the primary windings, a magnetic flux is created, which induces a current flow and voltage in the secondary windings.

Along with the core and the windings, a transformer requires insulation (to keep the windings from touching) and a cooling system (to prevent the transformer from overheating).

Transformers are used to change the voltage of electricity flowing in the circuit. They can increase the voltage (known as stepping up) or decrease voltage (stepping down) so it can be distributed at the right values for the circuit requirements.

Applications and benefits of transformers

Transformers are used in a variety of applications including power generation, transmission and distribution.

In power plants, transformers are used to increase the voltage of the electricity generated before it’s sent to the grid. At the other end, transformers increase or decrease the voltage to make it suitable for use in homes and businesses.

Smaller-scale transformers are also used in lighting, audio systems and electronic equipment such as computers, TVs and radios.

Transformers offer many benefits:

Efficiency: Transformers transfer electricity efficiently so less energy is lost in the form of heat, which results in lower energy costs.
Safety: Controlling your voltage reduces the risk of electrical faults which could pose a risk to your teams.
Reliability: Transformers are very reliable and have a long lifespan (when properly maintained).

Maintaining your transformers

When you have the right voltage levels, your electrical installations and equipment can operate more efficiently and effectively and will be less prone to electrical faults.
As with any electrical equipment, transformers require maintenance to ensure optimum safety and efficiency.

Regular visual inspections for signs of wear and damage can help you identify potential issues early.

Common issues include overheating, insulation failure, core saturation and short circuits caused by faults in the windings.

AES can test and inspect your transformers to ensure they are safe and efficient. We can also make recommendations for upgrades to your electrical power systems.

Upgrading your transformers

Transformers are a vital component in your electrical power system so it's worth paying attention to them. And, as with most technology, there have been advancements so there are plenty of opportunities for improvement.

The construction of your transformers is important and there are lots of options. Steel cores, laminated steel cores, toroidal cores and even air cores all have their place.

Then there’s the conductive material used for the windings which will depend on the application of the transformer. The materials used for insulation will also be a factor for consideration.

Eco-friendly transformer designs are becoming more common with the use of sustainable materials and biodegradable insulation oils.

As well as thinking about the construction of transformers, you can also integrate them with IoT and sensors for real-time monitoring and diagnostics. Having real-time data can help you identify potential issues before they arise, reducing the risk of failure or unplanned downtime.

Working with AES

At AES, we specialise in electrical contracting services for manufacturers. If you haven’t got a strategy in place for managing your electrical installations, we can help.

As well as proactive and reactive maintenance, we offer a range of specialist services to help you reduce downtime, improve power stability, and increase energy efficiency:

• Voltage optimisation
• Power factor correction
• Variable speed drives
• Energy-efficient lighting
• Battery Energy Storage Solutions (BESS)
• Uninterrupted Power Supply (UPS)
• Testing and inspecting any electrical installations
• Electrical vehicle charge points
• Solar installation
• Smart controls
• Control and automation systems

AES personnel are also CompEx accredited to work in ATEX areas.

If you’d like to learn more about how AES can keep your factory operating efficiently, get in touch with our expert team.