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<p>The increasing need for high-efficiency transformers, as well as lightweight electrical systems, necessitated the utilization of functional materials in winding applications. Copper windings are conventional and good from the conductivity point of view, but have a constraint related to weight and thermal problems, and thus require advanced solutions. Electrical conductors made of nonmetallic materials might represent a leap forward in technological growth and an attractive alternative to traditional wires. However, relative knowledge is missing both experimentally and analytically. This paper examines the potential of using new advanced novel carbon nanotube yarn (CNT), carbon nanotube–aluminium (CNT/Al), and carbon nanotube–copper (CNT/Cu) composite wires for the transformer winding. An extensive numerical investigation was implemented to measure the electrical performance of these materials in terms of output current and voltage. A finite element 3-D model of a single-phase transformer has been developed, which is employed in COMSOL Multiphysics® software to simulate the performance of the transformer. These results show that while the input conditions and load were kept constant across all simulations, the output voltages and currents vary significantly because of the differences in electrical resistivity and thermal conductivity among the materials used. The proposed Cu, CNT, CNT/Al, and CNT/Cu winding prototype step-up transformer generated maximum output voltages are 129.39&#xa0;V, 61.48&#xa0;V, 91.88&#xa0;V, and 113.67&#xa0;V, respectively. Moreover, the numerical simulation results indicated that a transformer manufactured from the novel carbon nanomaterials possesses behaviours as defined by the standard theory of the electrical transformer. The distinctive feature lies in the comparison of these CNT-based materials, which reveals the benefits of these materials, including less mass, higher thermal resistance, and an environmentally friendly option instead of copper windings. The present work expands the knowledge of transforming transformer technology through the use of CNT/Cu composites as a solution for efficiency and performance enhancement in future energy systems, based on the new challenges of the traditional material. Further, the numerical results obtained by the proposed method agree well with the previous experimental results, with a maximum relative error of 5.16%.</p>

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Numerical Investigation of Novel Carbon Nanomaterial-Based Wire for Electrical Transformer Windings: Performance Improvement and Future Prospects

  • 期刊论文

  • 发表日期：

    2025年10月27日

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  • Atazaz Hassan,
  • Sajid Abbas,
  • Zigang Deng,
  • Chen Quanfang,
  • Muhammad Shahid Mastoi,
  • Luo Youming,
  • Wang Li

摘要

The increasing need for high-efficiency transformers, as well as lightweight electrical systems, necessitated the utilization of functional materials in winding applications. Copper windings are conventional and good from the conductivity point of view, but have a constraint related to weight and thermal problems, and thus require advanced solutions. Electrical conductors made of nonmetallic materials might represent a leap forward in technological growth and an attractive alternative to traditional wires. However, relative knowledge is missing both experimentally and analytically. This paper examines the potential of using new advanced novel carbon nanotube yarn (CNT), carbon nanotube–aluminium (CNT/Al), and carbon nanotube–copper (CNT/Cu) composite wires for the transformer winding. An extensive numerical investigation was implemented to measure the electrical performance of these materials in terms of output current and voltage. A finite element 3-D model of a single-phase transformer has been developed, which is employed in COMSOL Multiphysics® software to simulate the performance of the transformer. These results show that while the input conditions and load were kept constant across all simulations, the output voltages and currents vary significantly because of the differences in electrical resistivity and thermal conductivity among the materials used. The proposed Cu, CNT, CNT/Al, and CNT/Cu winding prototype step-up transformer generated maximum output voltages are 129.39 V, 61.48 V, 91.88 V, and 113.67 V, respectively. Moreover, the numerical simulation results indicated that a transformer manufactured from the novel carbon nanomaterials possesses behaviours as defined by the standard theory of the electrical transformer. The distinctive feature lies in the comparison of these CNT-based materials, which reveals the benefits of these materials, including less mass, higher thermal resistance, and an environmentally friendly option instead of copper windings. The present work expands the knowledge of transforming transformer technology through the use of CNT/Cu composites as a solution for efficiency and performance enhancement in future energy systems, based on the new challenges of the traditional material. Further, the numerical results obtained by the proposed method agree well with the previous experimental results, with a maximum relative error of 5.16%.