Transformer Design

Transformer Design

The process of transformer design

Designing and specifying transformers is not always an easy tasks. There are many variations when designing transformers for specific applications. Over the last 35 years we have manufactured and repaired thousands of transformers which vary in application. This has given us a great deal of experience when designing and specifying transformers.

The construction of a standard transformer is a simple process and can be manufactured in less than a week. However, more complex transformer arrangements may need a lot more winding and construction time.

When ordering or specifying a transformer, it is important to know precisely what the application of the transformer is. This aids with the transformer design and specification of construction materials.

Basic Transformer Data

Before a transformer can be designed, knowing the application data is key. This list is the basic data required to design a transformer.

  • 1. Input voltage
  • 2. Output voltage
  • 3. Output power (kVA)
  • 4. Frequency
  • 5. Phases (Single phase or three phase)
  • 6. Ambient temperature
  • 7. Environment (Indoor or outdoor)
  • 8. Size restrictions
  • For more complex applications there may be a need for a lot more data before the design can be started.

    Transformer design

    There are many applications and uses for a transformer, so understanding the full scope of end application is important. Our team can aid you with this process if you are unsure of what you require. Read more about our custom made transformers here.

    When designing a transformer there are many elements to consider. The correct choice of lamination, transformer connections and transformer size and heat restrictions. This is to name just a few.

    Using this data we can produce a datasheet which can be incorporated in your design approval. The design datasheet we produce gives a full electrical overview of the transformer. This allows for specific elements to be calculated and changed before produced starts, if required.

    The environmental considerations are equally as important as the electrical data. By knowing the type of environment that the transformer will be located in, the design can be adjusted to accommodate this. To ensure the life expectancy of the transformer, it is important to install the transformer in the correct enclosure type. The two main elements which are taken into consideration are the material the enclosure is made out of and the IP rating.

    Larger outdoor transformers are usually oil filled transformers. This helps to protect the transformer from the elements and ensures a longer life expectancy.


    Designing a transformer as per a specific application can be easily achieved with the correct information. It is important to understand the full application of the transformer before starting the design process. This ensures the end solution is feasible, before going into production. For further reading click here.

    If all the data isn’t available beforehand, our technical team will be able to assist you with this. To discuss any requirements please free feel to contact Ian Aitchison on 0151 486 6760.

    Contact us

    If you would like to discuss any of our electrical contracting services please call us on 0151 486 6760