On the Feasibility of Localizing Transformer Winding Deformations Using Optical Sensing and Machine Learning

Mechanical vibrations induced by electromagnetic forces during transformer operation can lead to winding deformation or failure, an issue responsible for over 12% of all transformer faults. While previous studies have predominantly relied on accelerometers for vibration monitoring, this study explores the use of an optical sensor for real-time vibration measurement in a dry-type transformer. Experiments were conducted using a custom-designed single-phase transformer model specifically developed for laboratory testing. This experimental setup offers a unique advantage: it allows for the interchangeable simulation of healthy and deformed winding sections without causing permanent damage, enabling controlled and repeatable testing scenarios. The transformer’s secondary winding was short-circuited, and three levels of current (low, intermediate, and high) were applied to simulate varying stress conditions. Vibration displacement data were collected under load to assess mechanical responses. The primary goal was to classify this vibration data to localize potential winding deformation faults. Five supervised learning algorithms were evaluated: Random Forest, Support Vector Machine, K-Nearest Neighbors, Logistic Regression, and Decision Tree classifiers. Hyperparameter tuning was applied, and a comparative analysis among the top four models yielded average prediction accuracies of approximately 60%. These results, achieved under controlled laboratory conditions, highlight the promise of this approach for further development and future real-world applications. Overall, the combination of optical sensing and machine learning classification offers a promising pathway for proactive monitoring and localization of winding deformations, supporting early fault detection and enhanced reliability in power transformers.