COMTRAFO: simulation as a strategy for innovation in power transformers
See how the company optimized power transformer design, ensuring raw material savings and greater prediction accuracy
Faced with the technical demands of the energy sector and the entry into new product classes, COMTRAFO, a Brazilian manufacturer of transformers and reactors, recognized the need to innovate in design methodologies. Coupled physical phenomena and complex boundary conditions required a solution that went beyond traditional analytical tools.
The answer was the adoption of simulation solutions, which have become a fundamental pillar, redefining the engineering workflow from conceptual study to project optimization.
By using tools such as Ansys Maxwell® and Ansys Fluent®, COMTRAFO not only expanded its know-how in the electrical, magnetic, and thermal fields but also achieved tangible results. This includes the optimization of insulation distances, which generated significant cascading raw material savings, and the continuous improvement of equipment performance, allowing the company to serve projects with voltage classes up to 345 kV.
Challenge
COMTRAFO needed tools to expand the considerations used in analytical calculations to meet new challenges in the transformer sector, with increasingly rigorous specification demands.
Solution
COMTRAFO implemented Ansys simulation tools, with educational and technical-strategic support from ESSS. They were integrated into all stages of the product life cycle, from conceptual studies to redesign, enabling complex multiphysics analyses and the validation of innovations.
Results
The use of simulation resulted in an expansion of dielectric, magnetic, and thermal know-how, and significant raw material savings. An example was the reduction of electrical insulation distances, which led to a decrease in mass and an improvement in efficiency.
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