With the issuance of “Transformer Energy Efficiency Improvement Plan (2021-2023)”( Government Work Report ), it is clear that by 2023, the proportion of high-efficiency and energy-saving transformers in the network will increase by 10%, and the proportion of new high-efficiency and energy-saving transformers in that year will reach more than 75%. It is very important to promote the application of high-end oriented silicon steel and energy-saving transformer for energy conservation and emission reduction in China.
The energy saving effect of the three-dimensional winding core transformer is outstanding and the product structure is superior. After more than ten years of research and development, the structure design of the three-dimensional core transformer made in China is reasonable. Compared with the traditional laminated core transformer, it has many advantages such as energy saving, material saving, low noise and stable performance.
The no-load loss of amorphous alloy transformer is only half of that of S13 silicon steel three-dimensional coil core distribution transformer, and the energy-saving effect is more obvious.
The structure and manufacturing technology of the three-dimensional core is completely different from the laminated core, and it is also different from the plane core: The same cross-section area of the core column, the same window height size, the same center distance of the core.
We’ve created this handy table of contents if you want to skip ahead to the amorphous three-dimensional core transformer that are most interesting to you:
What you should know about amorphous solid core transformer?
1. What is amorphous three-dimensional core transformer?
2. Technical principle of amorphous three-dimensional core transformer
3. Main characteristics of oil immersed transformer with amorphous three-dimensional core
4. Advantages of amorphous three-dimensional core dry type transformer
5. Cost advantage of amorphous three-dimensional core transformer
6. Technical index of amorphous three-dimensional core transformer
7. Conclusion
1. What is amorphous three-dimensional core transformer?
Three dimensional wound core is a kind of wound core. The whole iron core is made up of three identical single frames. After assembling, the equilateral triangle three-dimensional structure has good stability, high mechanical strength and consistent three-phase stress, which enhances the short-circuit resistance of the body. The three core columns of the assembled iron core are arranged in equilateral triangle three-dimensional.
The existing amorphous alloy transformer core structure has two types, one is four frame five column type, the other is three frame three column type. The two types of amorphous alloy core structure are open plane wound core structure, the cross section of the coil is rectangular, mainly because the cross section of the amorphous alloy core column is rectangular.
Because the cross-section of the core column and coil are rectangular, the ability of resisting sudden short circuit is reduced, so it is necessary to take some remedial measures, such as structural strengthening and press fitting technology. Moreover, because of the use of flat wound core structure, the joints are more, resulting in the increase of noise.
Although these problems can be solved by increasing the input of raw materials and strengthening the body structure, the rise of comprehensive cost has a negative impact on the promotion and application of amorphous alloy transformer.
Under the same conditions, the transformer with three-dimensional wound core has lower noise and stronger anti sudden short circuit ability, and can effectively reduce the volume and weight of the transformer, and reduce the production and operation costs.
Therefore, the research of amorphous alloy three-dimensional wound core transformer which combines the advantages of the above two kinds of transformers has a wide application prospect and obvious social and economic benefits.
- Technical principle of amorphous three-dimensional core transformer
A.Magnetic path
Fig. 1 Schematic diagram of magnetic circuit (Right)and magnetic flux vector of amorphous alloy solid core (left)
The magnetic circuit of amorphous alloy solid core is analyzed theoretically. The phase a flux FA in the left figure is composed of F1 and F2 in two single frames, and the right figure is the vector diagram of each frame flux and core column flux. The results show that the magnetic density of yoke is 15.5% higher than that of core column.
B.Heat Treatment
Fig. 2 Schematic diagram of position of monitoring iron core and furnace temperature (left) and schematic diagram of insertion position of thermocouple (right)
This project is a heat treatment process combining multi thermocouple temperature measurement technology and hot air circulation differential diversion technology. The figure on the right shows the position of thermocouple insertion. According to the specification of iron core, insert thermocouple in the center of three or more different strips. The figure on the left is the location diagram of monitoring iron core and furnace temperature before. The former is a new temperature measurement technology, namely multi thermocouple temperature measurement technology, which can effectively control the internal temperature of iron core. The temperature difference in different parts of the same core can be effectively reduced by adding guide plate in annealing furnace and adjusting wind speed. The picture on the left shows the situation before the improvement. The temperature difference of different parts should reach 50 ℃. After the improvement, the temperature difference can be reduced to about 20 ℃.
After using thermocouple temperature measurement technology and hot air circulation differential conductivity technology, the performance parameters of amorphous alloy solid coil core can reach 0.35va/kg unit excitation power and 0.18w/kg unit loss at 1.35t magnetic density.
3. Main characteristics of oil immersed transformer with amorphous three-dimensional core
1) High strength of iron core
2) Strong short circuit resistance, three-phase balance, low noise
3) The hot spot is heated evenly.
4) Material saving
5) Low no-load loss, low no-load current
6) Small magnetic flux leakage
The amorphous alloy three-dimensional wound core transformer has many obvious advantages, which is far stronger than the traditional amorphous transformer in competition. We can boldly say that the amorphous alloy three-dimensional wound core transformer will be a new bright spot in the transformer market.
Amorphous alloy three-dimensional wound core transformer is a real “environmental protection guard”. In today’s social environment of advocating “green, environmental protection, low carbon” life, it is right time to promote amorphous alloy three-dimensional wound core transformer.
4. Advantages of amorphous three-dimensional core dry type transformer
5. Cost advantage of amorphous three-dimensional core transformer
We have known the advantages of amorphous alloy solid core transformer, but we still have some technical problems to solve.
According to the characteristics of hard, thin and brittle amorphous materials, the high-precision curve cutting machine and three-dimensional core winding machine are developed to control the cutting and winding more accurately, which can solve the technical difficulties of the cutting and winding of amorphous alloy materials, realize the integration of cutting and winding, and improve the production efficiency.
6. Technical index of amorphous three-dimensional core transformer
1) Main technical performance index
2) Comparison of similar technologies at different Suppliers
7. Conclusion
We firmly believe that no matter what manufacturing methods and production processes, efficient and safe operation is the meaning of amorphous transformer, and it will become the favourite of the industry.
SUM can make this core with great performance,for more information please contact us.
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