Thermal Effects of Harmonics on Distribution Transformers: A Coupled Electromagnetic–Thermal Finite-Element-Based Approach
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Abstract
The growing demand for electrical energy, together with increasingly complex operating conditions caused by nonlinear loads and the widespread integration of renewable energy sources, has led to increased harmonic distortion in power systems. As critical assets in distribution networks, transformers are particularly vulnerable to harmonic-induced losses and thermal stress, which can accelerate insulation aging and reduce service life. This study investigates the thermal effects of harmonics on a medium-voltage distribution transformer using a coupled electromagnetic–thermal approach based on the finite element method. In the proposed workflow, ANSYS Maxwell is used to compute electromagnetic quantities and harmonic-dependent losses, and these losses are then used as inputs to an equivalent electro-thermal model to predict top-oil and winding hot-spot temperatures. The electromagnetic model is validated under no-load and short-circuit conditions, and simulations are conducted for linear and nonlinear loads at 50%, 100%, and 125% of rated load. The hybrid thermal prediction results show good agreement with detailed ANSYS Mechanical simulations, with a deviation of approximately 3% in the linear-load case and 0.016% in the nonlinear-load case. The results show that harmonic loading significantly increases load-related losses and hot-spot temperature, while also revealing a non-uniform temperature distribution that enables hot-spot localization. The obtained spatial hot-spot information supports insulation loss-of-life assessment and provides practical guidance for design improvement, sensor placement, periodic inspection/testing, spare-part planning, and condition-based maintenance under harmonic operating conditions.
Keywords
current harmonics, electromagnetic-thermal modeling, finite element method, medium-voltage transformer, thermal behavior
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