Shell Transformer Core

Shell transformer core adopts ** “winding surrounded by + magnetic circuit around” core structure, mainly by the heart column, side yoke, iron yoke ** three core parts, the whole is horizontally placed stacked piece structure, the heart column for the rectangular cross-section, each heart column on both sides of the side of the yoke, the iron yoke and the side of the yoke connected to the formation of a closed magnetic circuit, the transformer winding The transformer winding is completely wrapped in it.

– Magnetic circuit: closed magnetic circuit design, the magnetic flux from the yoke into the core column, through the side yoke back to form a cycle, the magnetic path is shorter, less magnetoresistance, effectively improve the efficiency of magnetic energy conversion, reduce the leakage rate.

– Stacked sheet stacking: Adopting the full diagonal seam stacking process, the silicon steel sheets are stacked in interlocking layers to reduce the air gap in the magnetic circuit, increase the magnetic permeability, and at the same time reduce the vibration and noise of the core.

– Winding position: the winding nested in the core column, by the side of the yoke and the yoke completely surrounded, the core of the winding to form a mechanical protection and magnetic shielding double effect, not only to enhance the stability of the winding, but also to reduce electromagnetic interference.

Supporting display: shell-type transformer core structure labeling diagram, magnetic circuit direction schematic, core and winding assembly schematic

Shell-type transformer core production process

We have a complete shell-type transformer core automated production line, from raw material processing to the finished product factory, the whole process of independent production, refused to trade OEM, to ensure product quality and delivery time can be controlled, the core production process is as follows:

1. silicon steel sheet slitting: using high-precision longitudinal shear, the whole roll of silicon steel sheet according to the design size accurate slitting, to ensure that the dimensional accuracy and edge flatness of silicon steel sheet.
2. Precision cutting of stacked sheets: the CNC punching and shearing machine cuts the shaped and slanted seams of the slit silicon steel sheets to meet the requirements of the stacking process, and the cutting error is controlled in a very small range.
3. Stacking and assembly: Adopt automatic stacking equipment to complete the stacking of silicon steel sheets in accordance with the full diagonal seam process to realize precise alignment, and manually assist in completing the initial assembly of the iron core.
4. Iron core clamping and fixing: Special clamping device is used to clamp the stacked iron core uniformly to ensure the compact structure of the iron core, to avoid loosening due to vibration during operation, and to reduce the air gap at the same time.
5. Magnetic performance test: Through professional magnetic performance testing equipment, the core’s magnetic flux density, iron loss, magnetic permeability and other core indicators are comprehensively tested to ensure that they meet the standards.
6. Final inspection of finished products: final inspection of the appearance, size, processing accuracy, electrical insulation properties of the iron core, as well as sampling aging test, labeling and warehousing after passing.

Supporting display: the production process factory scene, automated production equipment, video, product testing process photographic images

Core application areas of shell transformer cores

Shell transformer core with low loss, high magnetic stability, strong short-circuit resistance core advantages, become the core supporting components of various types of transformers, widely used in electric power, industry, new energy and other fields of transformer manufacturing, the main application scenarios include:

– Power transformer: suitable for power transformers in power transmission and distribution system, to meet the needs of high-voltage, high-power power transmission and distribution, and improve the stability and energy efficiency of power grid operation.

– Distribution transformers: distribution transformers for cities, industrial parks, residential areas, adapted to the complex power distribution environment, with good anti-interference, short-circuit resistance.

– Industrial transformers: special transformers for machine tools, metallurgy, petrochemical and other industrial fields, adapted to the harsh operating environment of the industrial site, to meet the needs of high-precision, high-reliability production.

– High-voltage transform ers: high-voltage transformers used in high-voltage testing, power equipment testing and other fields, with accurate magnetic properties, to ensure the stable operation of high-voltage equipment.

– Special transformers: for the reactor, rectifier transformer, photovoltaic / wind power grid-connected special transformers supporting, according to the design requirements of special transformers can be customized core structure, to meet the new energy, rail transit and other emerging areas of development needs.

Shell-type transformer core vs. core-type transformer core

Customization Capability

Unlike our competitors, our core is one of our main strengths. Based on various customers’ transformer design specifications, applications and standards of implementation, we offer a comprehensive customization solution, so that the core fits flawlessly with the customer‘s application:

1. can do size customize: by the customer supplied drawing, we can do core length, width, height, B/w cross-section size of core column, side yoke and yoke for different powers as well as different transformer shape.
2. customized thickness: According to the iron loss, magnetic performance requirements, customized 0.23mm, 0.27mm, 0.30mm, 0.35mm and other different thickness of silicon steel sheet stack, also can adapt to the processing of special ultra-thin silicon steel sheet.
3. Customized silicon steel grades: customized cold rolled silicon steel wafers of various grades based on the cost and performance requirement of customers, available from conventional grade to high grade ultra-low loss silicon steel wafers.
4. Stacking structure customized: considering the magnetic circuit design requirements of the transformer, we can customize the stacking way of the stacked piece and the oblique joint angle to realize the best performance of the magnetic circuit, and accomplish the some special magnetic property index request.
5. Customer designed implementation standards: can meet the customer requirement of satisfaction, for export or domestic product of various international standards and domestic standard requirements according to IEC, ANSI, GB/T 6451, etc.

Customized manufacturing process Customers submit the design drawings/ technical requirements. -> Engineer‘s one-to-one technical docking.-> Customized solutions quotation -> Customer confirmation-> Sample manufacturing and testing.-> Mass production -> Logistics delivery.

Factory strength

Our company is a shell-type transformer core source manufacturer, and we have many years experience in this field, whose main business is the research and development, production and marketing of the transformer cores, and we can supply customers information from all over the world with quality core products and related services, the basis strength is as follows:

– Production experience: possessing over 20 years’ production experience in transformer core making, so we eagerly involved in shell core segmentation and become skilled in core processing technology and methods.

– Advanced equipment: with a complete automated silicon steel sheet slitting, cutting, stacking facilities. And professional magnetic, electrical performance testing equipment, to achieve automated and precise production, testing.

– Perfect quality system We have passed ISO9001 quality management system certification. Our products are in line with the international standards IEC, ANSI, and the process is strictly carried on according to the quality system for quality control, ensuring the stability of product quality.

– Excellently innovative R&D ability: we have dedicated R&D group and electro-mechanical engineers team, which can execute R&D on core structure optimization, magnetic performance improvement and specific technical problems of our customers.

– Global export layout: our products have been exported to over 30 countries and regions like India, Vietnam, Saudi Arabia, Germany, Brazil, Egypt, et. A, we possesses abundant oversea export experience and are blanketed with local customs and conventional standards.

– Stable production capacity. we owned a large standardized production workshop with large-scale production capacity, which is capable of satisfying customers’ purchase in large quantity, and can guarantee on-time delivery to providing customers with a stable supply chain guarantee.

Supporting display: factory panoramic view, standardized production workshop and production lines, imported advanced production/testing equipment, cooperating cases with overseas customers, obtained quality system certificate.