AUTOMATIC LOAD SHARING OF DISTRIBUTION

TRANSFORMER USING ARDUINO

UNIVERSITY COLLEGE OF ENGINEERING, OSMANIA

UNIVERSITY
PROJECT BY:-

1) CH SAI LOKESH – (1005-21-734010)

2) Ch VISHAL - (1005-21-734012)

3) J VISHASV REDDY - (1005-21-734024)

4) K SHANKAR - (1005-21-734029)

UNDER THE GUIDANCE OF:-

Dr. G.V. NAGALAKSHMI

ASSOCIATE PROFESSOR

UCE,OU

DECLARATION
1
This is to declare that the semester project entitled “AUTOMATIC
LOAD SHARING OF DISTRIBUTION TRANSFORMER USING
ARDUINO” submitted by

1. CH SAI LOKESH
2. CH VISHAL
3. J VISHASV REDDY
4. K SHANKAR

To University College of Engineering, Osmania University, in partial

fulfillment of the requirements for the fourth year second semester in
Electrical Engineering is record of identified work carried out by us
under the guidance and supervision of Dr G.V. Nagalakshmi. The results
embodied in this have not been submitted to any other university or
institute.

SIGNATUREOFGUIDE

2
 CERTIFICATE OF COMPLETION OF PHASE 1OF
ENGINEERING MAJOR PROJECT

This is to state that CH SAI LOKESH of Electrical Engineering

Department studying in University College of Engineering, Osmania
University has completed the underlying ground work for his
Engineering Major Project titled “AUTOMATIC LOAD SHARING OF
DISTRIBUTION TRANSFORMER USING ARDUINO” as per the
requirements of his course titled Major Project Phase 1 under the
guidance and supervision of Dr. G. V. Nagalakshmi.

SIGNATURE OF THE HOD SIGNATURE OF THE GUIDE

3
 CERTIFICATE OF COMPLETION OF PHASE 1OF
ENGINEERING MAJOR PROJECT

This is to state that J VISHASV REDDY of Electrical Engineering

Department studying in University College of Engineering, Osmania
University has completed the underlying ground work for his
Engineering Major Project titled “AUTOMATIC LOAD SHARING OF
DISTRIBUTION TRANSFORMER USING ARDUINO” as per the
requirements of his course titled Major Project Phase 1 under the
guidance and supervision of Dr. G. V. Nagalakshmi.

SIGNATURE OF THE HOD SIGNATURE OF THE GUIDE

4
 CERTIFICATE OF COMPLETION OF PHASE 1OF
ENGINEERING MAJOR PROJECT

This is to state that CH VISHAL of Electrical Engineering Department

studying in University College of Engineering, Osmania University has
completed the underlying ground work for his Engineering Major
Project titled “AUTOMATIC LOAD SHARING OF DISTRIBUTION
TRANSFORMER USING ARDUINO” as per the requirements of his
course titled Major Project Phase 1 under the guidance and supervision
of Dr. G. V. Nagalakshmi.

SIGNATURE OF THE HOD SIGNATURE OF THE GUIDE

5
 CERTIFICATE OF COMPLETION OF PHASE 1OF
ENGINEERING MAJOR PROJECT

This is to state that K SHANKAR of Electrical Engineering Department

studying in University College of Engineering, Osmania University has
completed the underlying ground work for his Engineering Major
Project titled “AUTOMATIC LOAD SHARING OF DISTRIBUTION
TRANSFORMER USING ARDUINO” as per the requirements of his
course titled Major Project Phase 1 under the guidance and supervision
of Dr. G. V. Nagalakshmi.

SIGNATURE OF THE HOD SIGNATURE OF THE GUIDE

6
 ABSTRACT

This project focuses on the development of a load-sharing system for distribution

transformers using Arduino microcontrollers. Distribution transformers often
experience uneven load distribution, leading to overloading, inefficiency, and
potential damage. This project proposes a cost-effective and automated solution to
address this issue.

The system uses Arduino microcontrollers, current sensors, and voltage monitoring
modules to measure the load on each transformer in real-time. Based on the load
conditions, the system redistributes the load among multiple transformers to
maintain optimal performance and prevent overloading. The proposed solution
integrates a relay-based switching mechanism controlled by the Arduino, ensuring
seamless load transfer with minimal downtime.

The project demonstrates the feasibility of enhancing the efficiency and reliability
of power distribution systems using modern microcontroller-based automation.
This innovation could significantly reduce the risk of transformer failures and
contribute to a more stable electrical grid, making it an impactful step towards
smarter energy management.

7
Contents
Contents..................................................................................................................................................8
CHAPTER 1. INTRODUCTION....................................................................................................................9
1.1BACKGROUND................................................................................................................................9
1.2. STATEMENT OF THE PROBLEM..............................................................................................10
1.3. OBJECTIVES............................................................................................................................12
2. PARALLEL OPERATION OF TRANSFORMERS...................................................................................13
2.1 DISTRIBUTION TRANSFORMER....................................................................................................13
2.2 PARALLEL OPERATION OF TRANSFORMER..................................................................................14
2.3. CONDITIONS FOR PARALLEL OPERATION....................................................................................16
2.4. ADVANTAGES OF PARALLEL OPERATION....................................................................................20
3. LOAD SHARING OF DISTRIBUTION TRANSFORMERS BY PARALLEL OPERATION USING ARDUINO. 23
3.1. OVERVIEW OF THE SYSTEM........................................................................................................23
3.2. COMPONENTS USED..............................................................................................................24
3.3. WORKING PRINCIPLE..................................................................................................................28
3.4. NO LOAD CONDITION.................................................................................................................32
3.5. SUFFICIENT LOAD CONDITION....................................................................................................33
3.6. OVERLOAD CONDITIONS.............................................................................................................34
3.7. ARDUINO CODE UTILIZED...........................................................................................................35
3.8. FORMULAE USED........................................................................................................................40
3.9. LOAD CONDITIONS TABLE...........................................................................................................41
3.10. TRANSFORMER STATUS TABLE.................................................................................................41
3.11. FEATURES AND FUNCTIONALITIES............................................................................................42
3.12. ADVANTAGES OF THE SYSTEM..................................................................................................43
4. DEMONSTRATION OF THE HARDWARE ASPECT............................................................................45
4.1 SUFFICIENT LOAD CONDITION.....................................................................................................45
4.2 OVER LOAD CONDITION..............................................................................................................47
5. FUTURE SCOPE...............................................................................................................................49
6. CONCLUSION.....................................................................................................................................50
7. REFERENCES...................................................................................................................................51

8
 CHAPTER 1. INTRODUCTION

1.1BACKGROUND

Electricity is one of the most versatile and widely used forms of energy in the
modern world. It is the backbone of industrial growth, economic development, and
technological advancement. In today’s rapidly industrializing and urbanizing
societies, the role of electrical energy has become indispensable, touching every
aspect of human life—from domestic appliances to advanced manufacturing
processes. Consequently, the demand for electrical energy continues to rise
sharply.

To meet this growing demand efficiently, electrical power systems have evolved
into highly complex, vast, and nonlinear networks that span across cities, states,
and even countries. These systems consist of power generation stations,
transmission lines, and distribution networks. For the sake of cost-effectiveness,
reliability, and operational convenience, these power systems are often integrated
into unified grids. However, while such unification brings benefits, it also
introduces significant challenges, particularly during transmission and distribution
of power.

One of the major challenges faced in electrical power systems is the inevitable loss
of electrical energy during transmission and distribution. These losses are mainly
attributed to long-distance power transfer, resistance in transmission lines, and the
widely scattered nature of both power sources and consumer loads. Distribution
systems, which are the final stage of electricity delivery to the end-users, suffer
from issues such as voltage and current imbalance, poor voltage regulation,
excessive peak power losses, and overheating of conductors or equipment. Among
these, phase voltage and current imbalances are critical, as they contribute

9
significantly to energy losses and can cause undue stress and overheating in
electrical equipment, particularly transformers.

A transformer is a static electromagnetic device that plays a pivotal role in the

transmission and distribution of electricity. It steps up the voltage for efficient
transmission and steps it down for safe usage at the consumer end. However, under
overload conditions, the transformer’s efficiency drops significantly. Prolonged
overloading results in excessive heating of the windings, especially the secondary
winding, which may eventually lead to insulation failure and transformer burnout.
Protecting transformers from such overload conditions is, therefore, crucial to
ensure the longevity and reliability of the entire power system.

This project aims to address the issue of transformer overloading in distribution

systems. The proposed solution involves automatic load sharing between two
transformers using an Arduino microcontroller. In this system, the Arduino
continuously monitors the load on the primary transformer and compares it against
a predefined reference value. When the load exceeds this threshold, the Arduino
activates a secondary transformer to share the excess load, thereby preventing
overload on the primary transformer and ensuring balanced operation.

1.2. STATEMENT OF THE PROBLEM

The transformer is a vital and indispensable component in the electric power

transmission and distribution system. It plays a central role in ensuring that
electrical energy generated at power stations is efficiently transmitted over long
distances and safely delivered to end-users at appropriate voltage levels.
Transformers operate on the principle of electromagnetic induction and are used to
step up the voltage for transmission purposes and step it down for distribution and
consumption. Their contribution to minimizing transmission losses and
maintaining voltage levels within permissible limits makes them a key element of
the entire electrical infrastructure.

10
However, despite their importance and robust design, transformers are prone to a
variety of operational issues—most notably overloading, voltage fluctuations,
and the heating effect. Overload conditions occur when the connected load
exceeds the rated capacity of the transformer. In such scenarios, the transformer is
forced to supply more current than it was designed for, leading to increased
internal losses in the form of heat. This excessive heating can significantly reduce
the transformer's efficiency and cause deterioration of the insulation around the
windings. In severe cases, the secondary winding may overheat to the point of
failure, potentially resulting in burning, short-circuiting, or even a fire hazard.

Voltage variations are another common problem associated with overloading,

where sudden load changes cause voltage drops or spikes, affecting the stability of
the electrical system. The persistent heating effect not only compromises the
internal components but also reduces the overall lifespan of the transformer. Once
damaged, transformers are difficult and expensive to repair or replace. Repairing a
transformer is a time-consuming process that often requires specialized equipment,
skilled personnel, and a complete shutdown of the connected load, leading to
further inconvenience and economic losses.

Given these challenges, the core focus of this work is to develop a system that
can protect transformers under overload conditions. The idea is to monitor the
transformer load continuously and take preventive action before a critical overload
occurs. The project involves designing an intelligent load management system
that can automatically detect overload situations and respond by redistributing or
sharing the load with an auxiliary transformer.

By integrating microcontroller-based control logic, current sensors, and relays, this

system aims to prevent the transformer from entering a dangerous overload state.
This proactive approach not only protects the transformer but also ensures
uninterrupted power supply and enhances the reliability and efficiency of the
overall power distribution system. The proposed protection mechanism, therefore,
has the potential to significantly reduce maintenance costs, prevent equipment
failure, and extend the operational life of critical electrical infrastructure.

11
 1.3. OBJECTIVES

The main objective of this project is to design and implement an automatic load
sharing system for distribution transformers using Arduino in order to protect
the transformers from potential damage due to overloading. In modern power
distribution networks, the problem of transformer overloading has become
increasingly common due to the continuous rise in electricity demand, unbalanced
load distribution, and population growth. Overloaded transformers are at risk of
excessive heating, efficiency reduction, insulation breakdown, and eventual failure,
which leads to costly repairs, equipment replacement, and disruption of power
supply to consumers.

This project aims to mitigate such issues by developing a smart and reliable
control system that can monitor the load on a distribution transformer in real-
time and compare it against a predefined safe threshold. When the load exceeds
this limit, the system automatically diverts the excess load to a second transformer,
thereby distributing the load between two transformers. This load balancing
mechanism ensures that neither transformer operates beyond its rated capacity,
effectively preventing overheating, insulation failure, and long-term
degradation.

12
 CHAPTER 2. PARALLEL OPERATION OF
TRANSFORMERS

2.1 DISTRIBUTION TRANSFORMER

A distribution transformer typically refers to a type of power transformer that

operates within a voltage range of 10 kV to 35 kV, with a maximum capacity of
up to 6,300 kVA, and is primarily used to deliver electricity directly to end-users
in residential, commercial, and small industrial areas. These transformers form the
final stage in the power distribution network, stepping down the high-voltage
electricity from transmission lines to a lower, usable voltage suitable for consumer
applications. Their strategic position in the network makes them essential for the
reliable and efficient delivery of electrical power.

The total energy loss in a distribution transformer is generally classified into two
categories: constant (or no-load) loss and variable (or load) loss. Constant loss,
mainly caused by core hysteresis and eddy currents, occurs whenever the
transformer is energized, regardless of whether it is supplying load or not. On the
other hand, variable loss depends on the magnitude of the load and primarily
includes copper losses due to the resistance of the windings. These losses vary with
the square of the load current. Understanding the operational patterns of these
losses is crucial, as it helps determine the economic operating range of a
distribution transformer, which can be derived by analyzing load conditions
throughout the day.

Despite their widespread use, the production of distribution transformers

involves relatively advanced technologies and strict manufacturing standards,
especially when aiming for high efficiency, low noise, and long service life. This
high technological demand, combined with increasing global electrification needs,
has led to intense market competition among manufacturers. However, in the
13
past, there was a general neglect toward energy conservation during the
production and operational lifecycle of these transformers. As a result, many
older models in service today exhibit significant energy inefficiencies and higher
operating costs.

In recent years, with the acceleration of global economic development, there has
been a growing emphasis on energy efficiency and environmental
sustainability. Governments, industries, and consumers alike are becoming more
conscious of the need to reduce energy wastage and carbon footprints. This shift in
perspective has triggered increased research and innovation in transformer
manufacturing technologies. Consequently, a new generation of energy-saving
distribution transformers has emerged, which are designed with improved core
materials (such as amorphous metals), optimized winding configurations, and
advanced cooling techniques to minimize both constant and variable losses.

Today, energy-efficient distribution transformers are being gradually adopted

by power utilities and industrial users around the world, as they not only reduce
operating costs but also support national and international goals related to
sustainable development, carbon neutrality, and green energy initiatives. As
the demand for reliable, efficient, and eco-friendly power solutions continues to
rise, the role of high-efficiency distribution transformers will become even more
critical in shaping the future of electrical infrastructure.

2.2 PARALLEL OPERATION OF TRANSFORMER

When the load demand exceeds the rated capacity of an existing transformer, a
practical and efficient solution is to connect two or more transformers in
parallel. This method not only accommodates the additional load but also
enhances the overall flexibility and reliability of the power distribution system. In
the context of Automatic Load Sharing of Distribution Transformers,
transformers are connected in parallel such that the additional transformers are
automatically brought into operation whenever the load on the primary transformer
crosses its safe threshold. This ensures that no single transformer is subjected to

14
overload conditions, thereby preventing overheating, efficiency loss, and potential
damage.

One of the key advantages of operating transformers in parallel is the improved

reliability and redundancy it offers compared to a single larger unit. In the event
of failure or maintenance shutdown of one transformer, the other transformer(s)
can continue to supply power—either fully or partially—thus ensuring
uninterrupted operation of the distribution system. This reduces the risk of total
system failure, which is especially critical in applications requiring high service
continuity, such as hospitals, data centers, and industrial plants.

Moreover, cost-effectiveness is another major benefit of using parallel

transformers. When additional load capacity is required, installing another
transformer in parallel is typically more economical than replacing the existing
transformer with a larger one. Not only is the initial investment lower, but the
cost of maintaining spare units is also reduced. For instance, in a system using two
transformers of equal rating in parallel, a spare unit of the same rating can serve as
a backup for either transformer. This is significantly less expensive than keeping a
spare for a large-capacity single transformer, which would involve higher
procurement and storage costs.

Furthermore, from an operational standpoint, parallel operation offers greater

flexibility in load management. Load can be distributed evenly between the two
units to maintain balanced operation, improve efficiency, and reduce losses. Also,
during periods of light load, one transformer can be turned off to save energy,
while both can operate during peak demand.

In addition, maintenance procedures become more manageable. One

transformer can be taken offline for routine inspection, testing, or repairs without
disrupting the power supply, as the other transformer can temporarily handle the
critical loads. This ensures continuous service availability and supports proactive
maintenance strategies.

In conclusion, connecting transformers in parallel for automatic load sharing is a

technically sound and economically viable approach to address increased load
demands in distribution systems. It enhances system reliability, operational
flexibility, and cost-efficiency, while also providing a built-in mechanism for

15
redundancy and fault tolerance. Therefore, the adoption of parallel transformers,
especially when managed through an automated system like Arduino-based
control, is a highly recommended practice in modern power distribution networks.

2.3. CONDITIONS FOR PARALLEL OPERATION

For transformers to operate in parallel effectively, certain conditions must be met

to ensure proper load sharing, avoid circulating currents, and maintain system
stability. These conditions include:

2.3.1 Same Voltage Ratio (Turn Ratio):

If the transformers connected in parallel have slightly different voltage ratios, then
due to the inequality of induced emfs in the secondary windings, a circulating
current will flow in the loop formed by the secondary windings under the no-load
condition, which may be much greater than the normal no-load current. The
current will be quite high as the leakage impedance is low. When the secondary
windings are loaded, this circulating current will tend to produce unequal loading
on the two transformers, and it may not be possible to take the full load from this
group of two parallel transformers (one of the transformers may get overloaded).

If two transformers of different voltage ratio are connected in parallel with same
primary supply voltage, there will be a difference in secondary voltages. Now,
when the secondary of these transformers are connected to same bus, there will be
a circulating current between secondary’s and therefore, between primaries also.
As the internal impedance of transformer is small, a small voltage difference may
cause sufficiently high circulating current causing unnecessary extra I2R loss. The
ratings of both primaries and secondaries should be identical. In other words, the
transformers should have the same turn ratio i.e. transformation ratio.

16
2.3.2 Same Polarity:

Polarity of transformer means the instantaneous direction of induced emf in

secondary. If the instantaneous directions of induced secondary emf in two
transformers are opposite to each other when same input power is fed to the both of
the transformers, the transformers are said to be in opposite polarity.

The transformers should be properly connected with regard to their polarity. If they
are connected with incorrect polarities then the two emfs, induced in the secondary
windings which are in parallel, will act together in the local secondary circuit and
produce a short circuit. Polarity of all transformers run in parallel should be same
otherwise huge circulating current flows in the transformer but no load will be fed
from these transformers. If the instantaneous directions of induced secondary emf
in two transformers are same when same input power is fed to the both of the
transformers, the transformers are said to be in same polarity.

2.3.3 Same Phase Sequence:

The phase sequence of line voltages of both the transformers must be identical for
parallel operation of three-phase transformers. If the phase sequence is an
incorrect, in every cycle each pair of phases will get short-circuited. This condition
must be strictly followed for parallel operation of transformers.

2.3.4 Identical Frequency:

The transformers must operate at the same frequency. A frequency mismatch

results in pulsating currents and uneven load distribution.

2.3.5 Similar Voltage Regulation:

17
The voltage regulation of each transformer should be nearly the same.
Transformers with significantly different voltage regulation will not share the load
proportionally.

2.3.6 Same Impedance Ratio:

If two transformers connected in parallel with similar per unit impedances, they
will mostly share the load in the ration of their KVA ratings. Here, load is mostly
equal, because it is possible to have two transformers with equal per unit
impedances but different X/R ratios. In this case, the line current will be less than
the sum of the transformer currents and the combined capacity will be reduced
accordingly. A difference in the ratio of the reactance value to resistance value of
the per unit impedance results in a different phase angle of the currents carried by
the two paralleled transformers; one transformer will be working with a higher
power factor and the other with a lower power factor than that of the combined
output. Hence, the real power will not be proportionally shared by the
transformers.

The current shared by two transformers running in parallel should be proportional

to their MVA ratings. The current carried by these transformers are inversely
proportional to their internal impedance.

From the above two statements it can be said that impedance of transformers
running in parallel are inversely proportional to their MVA ratings. In other words,
percentage impedance or per unit values of impedance should be identical for all
the transformers run in parallel.

When connecting single-phase transformers in three-phase banks, proper

impedance matching becomes even more critical. In addition to following the three
rules for parallel operation, it is also a good practice to try to match the X/R ratios
of the three series impedances to keep the three-phase output voltages balanced.

18
When single-phase transformers with the same KVA ratings are connected in a Y
bank, impedance mismatches can cause a significant load unbalance among the
transformers.

The per-unit impedance (on a common base) of the transformers must be nearly
identical. Variations in impedance cause unequal load sharing, with the
transformer having lower impedance taking a higher proportion of the load.

2.3.7 Same Phase Angle Shift: (zero relative phase displacement between the
secondary line voltages)

The transformer windings can be connected in a variety of ways which produce

different magnitudes and phase displacements of the secondary voltage. All the
transformer connections can be classified into distinct vector groups.

Group 1: Zero phase displacement (Yy0, Dd0, Dz0)

Group 2:180° phase displacement (Yy6, Dd6, Dz6)
Group 3: -30° phase displacement (Yd1, Dy1, Yz1)
Group 4: +30° phase displacement (Yd11, Dy11, Yz11)

In order to have zero relative phase displacement of secondary side line voltages,
the transformers belonging to the same group can be paralleled. For example, two
transformers with Yd1 and Dy1 connections can be paralleled.

The transformers of groups 1 and 2 can only be paralleled with transformers of

their own group. However, the transformers of groups 3 and 4 can be paralleled by
reversing the phase sequence of one of them. For example, a transformer with Yd1
1 connection (group 4) can be paralleled with that having Dy1 connection (group
3) by reversing the phase sequence of both primary and secondary terminals of the
Dy1 transformer.

One can only parallel Dy1 and Dy11 by crossing two incoming phases and the
same two outgoing phases on one of the transformers, so if one has a DY11
transformer, he can cross B&C phases on the primary and secondary to change the

19
+30-degree phase shift into a -30-degree shift which will parallel with the Dy1,
assuming all the other points above are satisfied.

Same KVA Ratings:

If two or more transformers are connected in parallel, then load sharing per centage
between them is according to their rating. If all are of same rating, they will share
equal loads.

Transformers of unequal kVA ratings will share a load practically (but not exactly)
in proportion to their ratings, providing that the voltage ratios are identical and the
percentage impedances (at their own kVA rating) are identical, or very nearly so in
these cases a total of than 90 per cent of the sum of the two ratings is normally
available. It is recommended that transformers, the kVA ratings of which differ by
more than 2:1, should not be operated permanently in parallel.

Transformers having different kVA ratings may operate in parallel, with load
division such that each transformer carries its proportionate share of the total load
To achieve accurate load division, it is necessary that the transformers be wound
with the same turns ratio, and that the percent impedance of all transformers be
equal, when each percentage is expressed on the kVA base of its respective
transformer. It is also necessary that the ratio of resistance to reactance in all
transformers be equal. For satisfactory operation, the circulating current for any
combinations of ratios and impedances probably should not exceed ten percent of
the full-load rated current of the smaller unit.

2.4. ADVANTAGES OF PARALLEL OPERATION

Parallel operation of transformers offers several advantages, including:

20
2.4.1 Increased Reliability and Redundancy:

If one transformer fails, the remaining transformers can continue to supply power,
reducing the risk of total system shutdown.

2.4.2 Improved Load Sharing:

Parallel operation ensures that the load is distributed among multiple transformers,
preventing overloading of a single unit.

2.4.3 Flexibility in Maintenance:

Transformers can be taken out of service for maintenance or repairs without

disrupting the entire system's power supply.

2.4.4 Scalability:
Additional transformers can be added in parallel to accommodate increased load
demand without replacing the existing system.

2.4.5 Improved Efficiency:

Operating multiple transformers close to their optimal load capacity reduces losses
and improves efficiency compared to using a single, oversized transformer
operating at partial load.

2.4.6 Reduced Capital Cost:

Instead of installing a single large transformer, multiple smaller transformers can

be used, which might be more cost-effective and easier to procure.

21
2.4.7 Voltage Regulation:

Parallel transformers help maintain better voltage regulation across the network, as
the load is balanced and the risk of overloading individual transformers is
minimized.

2.4.8 System Flexibility:

Transformers can be switched in or out depending on the load demand, allowing

for better adaptability to changing power requirements.

These advantages make parallel operation a common practice in power distribution

and industrial systems.

22
 CHAPTER 3. LOAD SHARING OF
DISTRIBUTION TRANSFORMERS BY
PARALLEL OPERATION USING ARDUINO

“LOAD SHARING OF TRANSFORMERS USING ARDUINO” involves

monitoring and redistributing the load among multiple transformers to prevent
overloading and improve system efficiency. Here's a detailed explanation of how
the system works:

3.1. OVERVIEW OF THE SYSTEM

This project employs a combination of Arduino microcontrollers, current and

voltage sensors, and relay modules to create an intelligent system capable of real-
time monitoring and control of the load on distribution transformers. The
primary goal is to prevent transformer overload by automatically managing the
load distribution between two transformers.

The Arduino microcontroller serves as the core processing and decision-making

unit of the system. It is programmed to continuously read data from current and
voltage sensors connected to the primary transformer. These sensors provide
accurate measurements of the electrical parameters, allowing the system to
determine whether the transformer is operating within safe limits or approaching
an overload condition.

A predefined threshold is set in the Arduino code, representing the maximum

safe operating load for the transformer. When the sensed load exceeds this
threshold, the Arduino triggers the relay module, which acts as a switching device.
The relay then connects an additional transformer in parallel, effectively
redistributing the excess load. This automatic load sharing prevents the primary
transformer from being overloaded and ensures both transformers operate within
their rated capacities.

23
The system works in a closed-loop control configuration, where continuous
feedback from the sensors allows the Arduino to make real-time decisions. As load
conditions fluctuate, the system dynamically adjusts transformer usage to maintain
optimal performance, reduce stress on the equipment, and enhance system
reliability.

This automated control mechanism eliminates the need for manual intervention,
significantly reduces the risk of transformer failure due to overheating, and
improves energy efficiency. Additionally, by using readily available components
like Arduino and relays, the system remains cost-effective, modular, and
scalable, making it suitable for both small-scale and large-scale power distribution
networks

3.2 COMPONENTS USED

3.2.1 Arduino Microcontroller: The Arduino microcontroller is a compact,

open-source development board widely used in electronics projects, embedded
systems, and rapid prototyping. It is built around Atmel AVR microcontrollers
such as the ATmega328, or in some cases, more advanced ARM-based
processors, depending on the model (e.g., Arduino Uno, Mega, Nano, etc.). The
Arduino platform is renowned for its simplicity, flexibility, and user-friendly
interface, which makes it highly accessible to students, hobbyists, and
professionals alike.

In this project, the Arduino functions as the central control unit, playing a pivotal
role in the Automatic Load Sharing of Distribution Transformers. It is
responsible for interfacing with current and voltage sensors, processing real-
time data, and executing control logic based on programmed algorithms. When
the Arduino receives input from the sensors, it analyzes the load on the transformer
and compares it with a predefined threshold value. If the load exceeds this
threshold, the Arduino generates a digital control signal to trigger the relay
module, thereby connecting a secondary transformer in parallel to share the load.

24
The Arduino’s built-in analog-to-digital converters (ADC) enable it to accurately
read sensor outputs in analog form and convert them into digital values for further
processing. Moreover, it supports digital I/O pins for controlling actuators such as
relays, as well as serial communication protocols (UART, I2C, SPI) for
interfacing with external devices or modules if needed.

3.2.2 Current Sensors (ACS712):A current sensor is an electronic device used

to detect and measure the flow of electric current through a conductor. It operates
by converting the current into a corresponding output signal—either a voltage
signal (analog) or a digital signal—which can be interpreted by a
microcontroller, such as an Arduino, or other data acquisition systems.

In this project, the current sensor plays a critical role by monitoring the current
drawn by each transformer, which is essential for implementing the automatic
load-sharing mechanism. By continuously sensing the current flow, the sensor
provides real-time feedback about the load condition of each transformer,
enabling the Arduino to decide whether to activate the second transformer for load
sharing.

The current sensor used in this system is likely based on Hall-effect technology or
a shunt resistor method, both of which are widely used in power monitoring
applications. A popular choice in Arduino-based projects is the ACS712 sensor,
which provides an analog voltage output proportional to the current flowing

25
through it. This analog signal is then read by the Arduino’s analog-to-digital
converter (ADC) to calculate the real-time current

3.2.3 Relay Modules (SPDT Relay):

A Single Pole Double Throw (SPDT) relay is an electromechanical switching

device that is widely used in electronic control systems to control high-voltage or
high-current circuits using a low-power signal. It consists of one input terminal
(common) and two output terminals—Normally Open (NO) and Normally
Closed (NC)—allowing it to route a signal or power between two different paths
depending on its energized state.

In the context of this project, the SPDT relay serves as a key switching
component in the Automatic Load Sharing of Distribution Transformers
system. The relay is responsible for shifting the load connection between a single
transformer and a parallel combination of two transformers based on commands
received from the Arduino microcontroller.

26
3.2.4 Transformers (12-0-12V Centre Tapped Transformer) :The main
distribution transformers used for the load-sharing process. These are the core
elements whose performance and load are monitored and managed by the system.
A center-tapped 12-0-12V transformer is a type of dual-output transformer
commonly used in power supply applications where both positive and negative
voltages are required. This transformer has a primary winding and a secondary
winding that is split into two equal parts, with a center tap (often grounded)
providing the reference point. The typical voltage configuration of a 12-0-12V
center-tapped transformer indicates that it provides a total secondary voltage of
24V, with the center tap offering a 0V reference point. The two outputs from the
secondary winding are +12V and -12V relative to the center tap, respectively.

230V AC Supply is taken from Switch ports and small Halogen bulbs are used to
simulate the load.
27
3.3. WORKING PRINCIPLE

Step 1: Data Acquisition

Current sensors are connected to the output lines of the transformers.

Voltage sensors monitor the voltage on the output terminals.

The Arduino continuously collects data from these sensors.

Step 2: Data Processing

The Arduino processes the current and voltage readings to calculate the load on
each transformer.

Load = Voltage × Current

If the load on any transformer exceeds a predefined threshold (e.g., 80% of its
rated capacity), the Arduino determines the need to transfer part of the load to
another transformer.

Step 3: Decision Making

Based on the available capacity of other transformers, the Arduino identifies the
best transformer to share the excess load.

A relay switching algorithm is used to select and activate the appropriate

transformer.

Step 4: Load Redistribution

28
The Arduino activates relays to connect additional transformers to the circuit.

The load is redistributed by adjusting the connection of feeder lines between

transformers.

The system ensures minimal interruption during the switching process.

Step 5: Real-Time Monitoring and Feedback

The system continuously monitors the new load distribution to ensure balance.

Any anomalies, such as excessive voltage drops or sensor errors, are displayed on
the screen or sent as alerts.

29
Figure 1 CIRCUIT FOR OPERATION

30
Figure 2 FLOWCHART OF OPERATION

31
3.4. NO LOAD CONDITION

No Load ADC Value = 512

No Load Current = 0A

32
3.5. SUFFICIENT LOAD CONDITION

Balanced Load ADC Value: - 615

Balanced Load Current:- 1.18A

33
3.6. OVERLOAD CONDITIONS

Overload ADC Value: - 754

Overload Current: - 2.21A

34
3.7. ARDUINO CODE UTILIZED

#include <LiquidCrystal_I2C.h>

LiquidCrystal_I2C lcd(0x27, 16, 2);

int current=A1;

int relay1=8;

void setup()

pinMode(current,INPUT);

pinMode(relay1,OUTPUT);

pinMode(11,OUTPUT);

pinMode(A0,OUTPUT);

digitalWrite(11, LOW);

digitalWrite(A0, HIGH);

digitalWrite(relay1, HIGH);

lcd.init();

lcd.backlight();

Serial.begin(9600);

35
delay(50);

lcd.setCursor(0, 0);

lcd.print("Automatic T/F ");

lcd.setCursor(0, 1);

lcd.print("Load sharing s/m");

delay(3000);

lcd.clear();

void loop()

unsigned int a,b;

a=b=0;

int sensorValue1 = 0;

while(1)

sensorValue1 = analogRead(current);

delay(10);

lcd.setCursor(0, 0);

lcd.print("I:");

lcd.print((sensorValue1*10));

lcd.print(" ADC value ");

36
Serial.println(sensorValue1/3.2);

delay(500);

if((sensorValue1*10)<5100 && (sensorValue1*10)>5070)

if(b==0)

lcd.setCursor(0, 1);

lcd.print("T/F-1 ON ");

digitalWrite(relay1, HIGH);

a=1;

delay(6);

else if((sensorValue1*10)<5050)

digitalWrite(11, HIGH);

digitalWrite(A0, LOW);

delay(500);

lcd.setCursor(0, 1);
37
lcd.print("Sharing T/F... ");

digitalWrite(11, LOW);

digitalWrite(A0, HIGH);

delay(1500);

lcd.setCursor(0, 1);

lcd.print("T/F-1,2 ON ");

digitalWrite(relay1, LOW);

a=b=1;

delay(6);

/* else

if(a==0)

lcd.setCursor(0, 1);

lcd.print("T/F-1,2 OFF");

digitalWrite(relay1, LOW);

digitalWrite(relay2, LOW);
38
 delay(6);

}*/

This program implements automatic load sharing for distribution transformers

using an Arduino, a current sensor, relays, and an I2C LCD display. The system
continuously reads the current flowing through Transformer 1 using the sensor
connected to analog pin A1. The Arduino processes this analog value to determine
the transformer load.

If the current reading is within a normal operating range (around 5070–5100 after
scaling), it means only Transformer 1 is active, and the LCD displays “T/F-1
ON”. If the load exceeds a lower threshold (less than 5050), indicating potential
overload on Transformer 1, the Arduino activates a second transformer by
triggering additional control pins and relays. This action distributes the load
between both transformers, which is shown on the LCD as “Sharing T/F...”
followed by “T/F-1,2 ON”.

The system also prints current values to the Serial Monitor for debugging or
monitoring purposes. Some parts of the code (like turning off both transformers)
are commented out, possibly for future improvements or testing.

Overall, this code automates transformer load sharing based on real-time current
sensing, helping protect transformers from overload and enhancing reliability.

39
3.8. FORMULAE USED

i) Voltage = (ADC Value/1024)*5000

ADC value is the maximum analog reading from the sensor.

ii) Current = (Voltage – Offset Voltage)/ (Sensitivity)

Offset Voltage = 2500mV

Sensitivity = 20

iii) Current (A) = (sensorValue−512)/38

40
 3.9. LOAD CONDITIONS TABLE

Condition Offset ADC Value Current

Voltage
No Load 2.5V 512 0A
Balanced 3.003 V 615 1.04 A
Load
Overload 3.6815 V 754 2.21 A

3.10. TRANSFORMER STATUS TABLE

Condition Loads Current Power Transformer

(A) (VA) (Tr)
No Load 0 0A 0 VA Tr2 ON, Tr1 OFF
Balanced L1, L2 1.04 A 12.48 VA Tr2 ON, Tr1 OFF
Load
Overload L1, L2, 2.21 A 26.5 VA Tr2 ON, Tr1 ON
L3, L4

41
3.11. FEATURES AND FUNCTIONALITIES

3.11.1 Automatic Load Sharing:

The system operates automatically without the need for manual intervention,
continuously monitoring the load on the transformers in real time. By dynamically
managing and redistributing the electrical load whenever necessary, it ensures
uninterrupted and efficient operation, enhances the longevity of the
transformers, and minimizes the risk of overload-induced failures. This automation
contributes to improved system reliability, reduced maintenance costs, and
optimal performance of the power distribution network.

3.11.2 Protection Mechanism:

The system incorporates intelligent logic to detect overloading, short circuits, or

other electrical faults by continuously analyzing real-time data from current
sensors. Upon detecting abnormal conditions, the microcontroller can trigger
warning alarms or automatically shut down the affected transformer to prevent
damage, ensure personnel safety, and maintain system integrity. This proactive
fault detection and response mechanism significantly enhances the reliability,
protection, and automation of the distribution network.

3.11.3 Scalability:

The system is scalable and flexible, allowing additional transformers to be

seamlessly integrated by modifying the Arduino’s control logic and
incorporating the necessary hardware components, such as extra current sensors,
relays, and switching circuitry. This modular design makes it adaptable to growing
power demands and ensures that the load can be effectively distributed across
multiple transformers, thereby enhancing the capacity, reliability, and efficiency
of the distribution network.

42
Energy Efficiency:Balancing the load across multiple transformers not only
prevents overloading of any single unit but also avoids underutilization of others,
ensuring that all transformers operate within their optimal efficiency range. This
balanced distribution of electrical demand leads to improved energy efficiency,
reduced power losses, and enhanced lifespan of the equipment, ultimately
contributing to a more stable and cost-effective power distribution system.

UNOR3

3.12. ADVANTAGES OF THE SYSTEM

3.12.1Overload Protection: Automatically prevents transformer damage by

sharing excess load with another transformer when the primary one is overloaded.

3.12.2Uninterrupted Power Supply: Ensures continuous power delivery by

redistributing load before failure occurs, reducing downtime.

3.12.3Improved Transformer Lifespan: Avoids overheating and stress on a

single transformer, thereby extending the operational life of all transformers
involved.

3.12.4Real-time Monitoring: Continuously monitors current through sensors,

enabling quick response to changes in load.

3.12.5Efficient Load Management: Balances load dynamically, reducing energy

losses due to overloading or underutilization.

3.12.6Cost-effective: More economical than replacing an overloaded transformer

with a larger one; uses modular hardware like relays and Arduino.

3.12.7Scalable Design: Can easily integrate more transformers by updating the

code and adding hardware, making it future-ready.

43
3.12.8Reduced Maintenance Costs: Early detection and prevention of faults
reduce wear and tear and the frequency of maintenance interventions.

3.12.9Automated Operation: Eliminates the need for manual supervision and

switching, minimizing human error and labor.

44
 CHAPTER 4. DEMONSTRATION OF THE
HARDWARE ASPECT

4.1 SUFFICIENT LOAD CONDITION

When sufficient load, that is the amount of load that can be handled by a single
transformer, is applied only the Transformer on the left (T1) Under normal load
conditions, the electrical demand from the consumers is within the rated capacity
of the primary transformer. At this stage, only one transformer — the main
transformer — is active and responsible for supplying power to the connected load.
A current transformer (CT) installed in series with the load continuously senses the
current flowing through the system. This analog current signal is converted into a

45
voltage signal and then passed to the microcontroller through an Analog-to-Digital
Converter (ADC). The microcontroller reads this digital value and compares it
against a predefined reference value that has been programmed based on the safe
current carrying capacity of the main transformer.

If the measured current value is less than or equal to the reference value, the
microcontroller takes no switching action. It keeps the standby transformer
disconnected, ensuring that the system operates in its most efficient configuration.
Keeping the standby transformer idle during normal load conditions helps to
reduce energy losses, prevent unnecessary switching, and extend the operational
life of the transformer.

During this state, the microcontroller continues to monitor the system in real time.
It updates the LCD display with current readings such as the actual load current,
system status, and any warnings or alerts. The LCD may also log time-stamped
data, helping identify peak usage times or repetitive load patterns. This data can be
valuable for energy auditing and future load planning.

The normal load operation ensures:

 Minimal wear and tear on transformers.

 Higher system efficiency.

 Cost-effective and energy-saving operation.

 Continuous real-time monitoring.

The system remains in this mode until the load increases beyond the threshold.

46
4.2 OVER LOAD CONDITION

As the load increases and the current drawn exceeds the reference limit, the system
automatically detects an overload condition. This threshold breach triggers an
internal interrupt in the microcontroller, causing it to execute a programmed
routine for load sharing.

In this condition, the microcontroller immediately sends a control signal to

energize a relay. This relay, in turn, activates the circuit breaker that connects the
standby transformer in parallel with the main transformer. Once connected, the
load is distributed evenly or proportionally between both transformers, effectively
reducing the stress on the main transformer and avoiding potential overheating or

47
damage. This load sharing also helps maintain a stable voltage level across the
system, improving the quality of power delivered to the end-users.

The system continues to monitor the combined load current. If the load stabilizes
and falls back below the reference threshold over a period of time, the
microcontroller deactivates the relay, disconnecting the standby transformer to
return to single-transformer operation.

However, in cases where the load continues to rise and exceeds the combined
rated capacity of both transformers, the system initiates a priority-based load
shedding mechanism. Consumers or connected devices are categorized based on
priority (e.g., hospitals, traffic signals, essential services as high priority; street
lights or advertising boards as low priority). The system disconnects the lower-
priority loads to ensure continuous and safe power supply to critical systems.

This part of the logic ensures that even in overload situations:

 The overall power system remains safe.

 High-priority consumers receive uninterrupted power.

 Transformers are protected from overloading or failure.

The LCD plays an important role during this mode. It shows:

 Real-time load current.

 Transformer status (active/inactive).

 Overload warning messages.

 Details of any disconnected loads (due to priority-based shedding).

 Duration of overload conditions or peak usage.

Additionally, alarms or LED indicators can be integrated to alert maintenance

personnel in case of repeated overloads, ignalling the need for infrastructure
upgrades.

48
 CHAPTER 5. CONCLUSION

The "Load Sharing of Distribution Transformers Using Arduino" project

successfully demonstrates a cost-effective and efficient solution to address the
challenges of transformer overloading in power distribution systems. By
integrating Arduino microcontrollers with current and voltage sensors, the system
ensures real-time monitoring and intelligent load redistribution among
transformers.

This automated approach enhances the reliability, efficiency, and lifespan of

transformers, reducing the risk of failures and maintenance costs. Additionally, the
scalability of the system allows for easy integration of additional transformers to
meet increasing power demands.

The project highlights the potential of microcontroller-based automation in

modernizing power distribution networks, providing a stepping stone toward
smarter and more sustainable energy management. It also showcases the practical
application of engineering principles, contributing to the advancement of
technology in the electrical domain.

In conclusion, this project not only addresses a critical issue in the power sector but
also sets the stage for further innovations in the field of transformer automation
and energy optimization.

49
 CHAPTER 6. FUTURE SCOPE

The project describes about how to use power supply intelligently under peak
loads. The project automatically connects and disconnects the transformer thus
protecting transformer from overload. Sensing unit, i.e. Current transformer plays
an important role by sensing the current through the load and sending feedback
signal to the microcontroller. PIC Microcontroller is so programmed that as soon
as the load exceeds a particular current limit it will soon generate a control signal
that would be amplified by the driver unit and finally control signal is fed to the
relay. The switching process occurs in the Relay which automatically connects the
transformer in parallel in accordance to the load sensed by the CT.

The future scope of our project is particularly in Substation. In substations

particularly during the peak hours there is a need for the operation of additional
transformer to supply the additional load requirement. Our project automatically
connects the transformer under critical loads. Thus there is no need to operate both
transformers under normal loads, particularly during off peak hours. Thus power is
shared intelligently with the transformers in parallel.

50
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