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I n n ovat io nin Tra n s fo r m e r C o r e s a n d M a n u fa c t u r in g
April 2010
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B A S I C I N F O R M A T I O N
H I S T O R Y O F T H E U N I C O R E T E C H N O L O G Y
Detail of DUO3
AEM Cores Pty Ltd began operations in 1958 as a man-ufacturer of arc welders. Shortly after it began produc-tion of cut cores (C cores). From the 1970’s AEM was the leader in specialist wound core manufacturing in Australia, producing single and three phase cut cores, toroidal cores in GOSS and Mumetal (NiFe) materials, and Distibuted Gap Cores. Today, AEM is the only spe-cialist wound core manufacturer in South East Asia.
Because the market being served is small and very de-manding of “special designs“, AEM has for many years developed its own specialist machinery. During the late 1980’s and early 1990’s the high cost of manufactur-ing the labour intensive cut cores forced AEM to look for methods of increased automation. The philosophy of AEM, driven by the founder and owner, Bill Jenkinson, has always been to strive for greater and greater trans-former efficiency through innovative core design.In the mid-1990’s engineers at AEM produced pro-totype machinery to produce Unicores. The Unicore Technology was successfully used for some time by AEM and its customers before large core manufactures visit-ing from overseas saw it. They immediately wanted to buy the Unicore machine so that they could provide the advantages of Unicore products to their markets.More than 200 machines have been manufactured and Unicores are now being produced* or used in the fol-lowing countries:
Australia*BeneluxBrasil*Canada*Chile*Colombia*Czech Republic*Egypt*FranceIndia*Italy*Korea*Macedonia*
Malaysia*Mexico*New Zealand*NorwayPoland*Russia*South Africa*Spain*Turkey*United Arab Emirates*United KingdomUSA*Venezuela*
A D V A N T A G E S
The Unicore technology is very flexible, highly accurate, repeatable and reliable. Unlike production of toroidal and cut cores, it does not require any fixed tooling, such as various jigs and mandrils. Unicore laminations are fully formed when leaving the machine.
For General Purpose Transformers, Unicores have lower losses than cut cores or E&I and 90° Cut Laminations. Core assembly is very fast.
For Distribution Transformers, Unicore technology provides a highly flexible, accurate and reliable produc-tion system with all inherent advantages of wound core technology.
The latest development is the DUO core. It is a low loss Unicore designed for easy assembly. This core is expect-ed to slowly replace the use of large E&I, strip lamina-tions and C cores.We feel that ever tightening enviromental standards and efficiency requirements will drive the market towards high efficient Unicore poducts further in the future.
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U N I C O R E S
Similarly as toroidal or cut cores, Unicores belong to the family of wound magnetic cores. Historically there are more than ten different types of Unicores. Some of them are not used any more as they were replaced by better types.
Unicores can be used for Distribution Transformers and General Purpose Transformers from less than 1000 VA to approx. 1500 kVA. According to latest knowledge a 10.000 kVA transformer has already been produced using our cores.
M A T E R I A L S F O R U N I C O R E S
Unicores can be produced from any grade of Grain Oriented Silicon Steel (GOSS) with thickness from 0.2 to 0.35 and strip width from 20 to 300 mm. Two strips can be run simutaneously when using less than 140 mm strip.
It has been tested that some finer grades of GOSS can be also used for Unicores. For details please contact us.
U N I C O R E G E O M E T R Y A N D S I Z E S
Unicores can weigh up to 1500 kg. A Unicore is de-fined by the following parameters:
Window Length (WL) Window Width (WW)Strip Width (SW) Build-up (BU)Strip Thickness (ST) Corner AngleTightness Factor (TF)
Unicore faces can be straight butt, DUO-core, Distrib-uted Gap or Uncut. Unicores can be produced with 30°, 45° or 90° corners, depending on application. All these values can be easily specified and pro-grammed.
New Unicore types are continually developed.
Adjustable assembly plate
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Zucchiatti Elettromeccanica, Italy
U N I C O R E M A C H I N E S I N E U R O P E
More than 20 Unicore machines are operating in Europe now.
Traser, Italy Stalprodukt, Poland
ALCE Elektrik, Turkey
Elesa Transformadores, Spain Makitel, Macedonia
T H E U N I C O R E M A C H I N EA D V A N T A G E S
The Unicore machine is fully programmable computer controlled machinery. Therefore, it represents a very flexible production technology. Just by selecting a core type and entering core dimensions in the core definition file, one can easily produce a single core or a big volume of cores. Just-in-time production results in low level of inventory. No tooling is needed.
Core design screen
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Pskovelektrosvar, Russia
Vakar, Czech RepublicTechnotron, Czech Republic
INTEPS, Russia
Russkij Transformator, RussiaMetod, Russia
Therma FM, Czech Republic
Elektromashina, Russia
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D U O C O R E
A P P L I C A T I O N
DUO core is the newest type of Unicore. It is a low loss, price competitive core with very easy assembly. It is used for core-type, single-leg and shell-type, single and 3-phase General Purpose Transformers. Annealed DUO cores with one lamination per overlap may be used for Distribution Transformers.
After assembly into windings TIG welding of the last lamination and wedging is recommended.
D U O C O R E T Y P E S
To reduce assembly time, the number of laminations per overlap may be increased from 1 up to 3. Increasing from 1 to 2 results in a 45 % decrease in assembly time, and 2 to 3 results in a further 25 % decrease. Note that losses and magnetizing VA will increase.
D U O S I Z E S
Dimension Minimum (mm) Maximum (mm)Window Length (WL) 80 Unlimited*Window Width (WW) 40 Unlimited*Strip Width (SW) 20 (with two strips) 300 (with one strip)Build Up (BU) Material Thickness Unlimited*
* Not limited by the Unicore machine. Limited only by prac ti cal trans form er manufacturing considerations.
M A T E R I A L
Any grade of GOSS, thickness 0.2 to 0.35 mm.
O P T I O N A L A N N E A L I N G
Annealing reduces losses by 10 to 30 %, depending on the core size.
N O B A N D I N G
Simple TIG weld of final lamination only.
DUO3 core
DUO1 male half
3-ph DUO3 with corner holes
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D I S T R I B U T E D G A P C O R E S
A P P L I C A T I O N
DG Unicores represent a family of cores with a single cut per lamination. They are used for single-leg and shell-type, single and 3-phase Distribution Transformers.
Unlike traditional technology of producing DG cores, no tooling is needed for production of DG Unicores.
D G U N I C O R E T Y P E S
There are several different types of DG Unicores, namely a core with straight cut face, Diverging face (cascade of cut faces fans out) and End-Overlap (spirally wound laminations) face. The position and specification of the DG face can be easily programmed.
D G U N I C O R E S I Z E
Dimension Minimum (mm) Maximum (mm)Window Length (WL) 60 Unlimited*Window Width (WW) 40 Unlimited*Strip Width (SW) 20 (with two strips) 300 (with one strip)Build Up (BU) Material Thickness Unlimited*
* Not limited by the Unicore machine. Limited only by prac ti cal trans form er manu-facturing considerations.
M A T E R I A L
Any grade of GOSS, thickness 0.2 to 0.35 mm.
O P T I O N A L A N N E A L I N G
Annealing reduces losses by 10 to 30 % depending on the core size and is almost always desirable to achieve the highest efficiency.
3-ph DG core
40 kg single-phase DG core
End-Overlap type of DG core
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S I N G L E P H A S E D U O C O R E A S S E M B LY
P R O C E D U R E
1. Insert the first full size inner lamination into the coils. 2. Insert the smallest male packet. 3. Insert the helper strips. 4. Insert the corresponding female packet and then remove the strips. 5. Now repeat the steps 2 to 4 until all packets including the last female half with the outer welding lamination have been inserted. 6. After welding the outer lamination an insulation material may be used to lightly wedge the remaining space between the core and the coil.
The disassembled core Female half of the core
Male half of the corePartly assembled core without bobbins
DUO3 detail
E X A M P L E O F A S I N G L E P H A S E D U O 3 C O R E A S S E M B L Y
Core size: WL 210, WW 60, SW 70, BU 60 mmCore weight: 21 kg Transformer power: 7.5 kVACore production time: 18 min Core assembly time: max 4 min
Assembly plates
1
2
3
4
5
6
Taking a male packet Taking a female packet
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TH R E E P H A S E D U O C O R E A S S E M B LY
First inner core assembled Inserting female packet
Wedging the inner cores
Inserting first lamination
Strapping the core Start of outer core assembly
An assembly table
P R O C E D U R E
Assembly of a three phase DUO core is very similar to the single phase DUO assembly. Start with assembly of the first inner core into the coils. After the second inner core is assembled insert an insulation material to wedge the in-ner cores apart so that the first outer male packet fits accurately. Last lamina-tion of the inner cores may be welded. Now insert the outer core.
E X A M P L E O F A C A S T R E S I N T R A N S F O R M E R
Core weight: 164 kgTransformer power: 50 kVACore production time: 41 minCore assembly time: approx. 50 min
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ASS E M B LY O F A S I N G L E PH A S E DG CO R E
2 5 K VA D R Y T R A N S F O R M E R W I T H D G C O R E
Core size (DG): WL 300, WW 160, SW 130, BUP 67Core weight: 73 kgCore production time: 21 minCore assembly time: approx. 45 min
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CR U C I F O R M UN I C O R E S
2 5 K VA D R Y D I S T R I B U T I O N T R A N S F O R M E R W I T H D D G C O R E
Core size (DDG): WL 280, WW 128, SW 60/90/120, BU 116 mmCore weight: 152 kgCore production time: approx. 70 minCore assembly time: approx. 60 min
1 0 0 K VA D I S T R I B U T I O N T R A N S F O R M E R W I T H D U O 2 C O R E
Core size: WL 345, WW 120, SW 55/75/105/120/135/145, BUP 138Core weight: 284 kgCore assembly time: approx. 60 minutes
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O T H E R T Y P E S O F U N I C O R E S
S T E P B U T T C O R E
This type of Unicore is used only for a shell type Gen-eral Purpose Transformers to replace laminations, up to approx. 2 kVA. Its losses are much higher than DUO or DG Unicores, lower than or comparable to a C core but much lower than laminations.
B U T T - 2 A N D B U T T - 3 C O R E S
These cores have a gap of programmable size in 2 (sin-gle phase) or 3 (3-phase) legs. They are used in chokes and reactors.
Replacement of laminations, 1600 VA
Butt-2 core from 8 strips, approx. 850 kg
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G A P P E D C O R E
It is a core with one gap of programmable size in one leg only.
U N C U T C O R E
It is a core with no cuts. The Unicore machine is only feeding and folding steel.
Uncut cores are used for Current and Volt-age Transformers. They are always annealed to achieve the lowest loss and magnetizing current.
S T R A I G H T L A M I N A T I O N S
The Unicore machine can be programmed to produce rectangular 90° cut laminations which can be used for the manufacture of chokes and transformers.
WLUB
WW
Demagnetizing ball bearings
Uncut core for Petersen coil
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S A V I N G S W I T H U N I C O R E
U N I C O R E T R A N S F O R M E R
Core: Unicore DUO2 without annealingA Window: 155 × 60, Strip width: 90, Buildup: 50, Core weight: 20 kgB Window: 122 × 50, Strip width: 70, Buildup: 40, Core weight: 16,5 kg
Technical parameters:A Induction: 1.4 T, Current density: 3.3 A/mm², No-load loss: 70 W B Induction: 1.3 T, Current density: 3.0 A/mm²
Dimensions:A Width 210 × Depth 155 × Height 270B Width 260 × Depth 160 × Height 210
Total weight:A 31 kgB 26 kg
C L A S S I C A L L A M I N A T E D T R A N S F O R M E R
Dimensions:A Width 240 × Depth 153 × Height 310B Width 264 × Depth 132 × Height 228
Total Weight:A 39 kgB 31 kg
A Single Phase Transformer 5000 VA B Three Phase Transformer 3000 VA
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U N I C O R E P R O D U C T I O N T I M E SAs a guide a MS Excel spreadsheet is offered. By entering dimensions, production time and weight of single and 3-phase DUO and DG cores are calculated. Loading two strips less than 140 mm wide doubles capacity of the machine.
A N N E A L I N G U N I C O R E SUnicores are fully formed by the machine. It means they do not have to be annealed if higher losses can be accept-ed. Depending on application, core size etc. one can decide that annealing is not necessary. With increasing size of a core the difference in losses between unannealled and annealed core is getting smaller.
Unicore Production TimesEnter Core Dimensions
WL 240 mmWW 80 mmSW 80 mm Strip Width is less than 130 mm, load two
strips and double productionBUP 80 mmST 0,30 mm
Note: The calculated cycle time is for one strip, loading two strips will halve the unit time and double production.Single Phase Cores min : sec Core Mass (Kg) Output (Kg/hr)DUO C core with 45deg corner 24:03 43 107
Distributed Gap (DGap, DDGap, EOLap) with 45deg corner 21:43 43 11930deg corner 27:54 44 95Three Phase Cores min : sec Core Mass (Kg) Output (Kg/hr)DUO E core with 45 deg corner 35:18 69 117
Distributed Gap (Ecore and Elap) with 45deg corner 35:05 69 11830deg corner 42:08 70 100Disclaimer: This spreadsheet is offered as a guide only, it’s accuracy cannot be guaranteed. Data is derived by graphical interpolation of empirical tests on actual cores made on a standard UCM2500 machine at AEM Cores Pty Ltd. Tightness Factor is assumed to be zero (default), increasing the TF will increase the core mass slightly. Dec03
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mm5.93 = dliuB eroCgk1.9 = ssaMm54.0 = htap naeM
The manual magnetic test rig includes a variac connected to a power meter with either a single phase or three phase test leads around the test core.
Test results can be entered into the spread-sheet producing a graph showing interpo-lated core performance vs flux density for both Power Loss (Watts) and Magnetising Force (A/m).
MANUAL MAGNETIC TEST RIG FOR
TESTING SINGLE & THREE PHASE UNICORES
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E X A M P L E S O F U N I C O R E T R A N S F O R M E R S
Shell-type DUO core transformer, Italy
Petersen coil with DG coresSingle-leg transformer Core type transformer
100 kVA transformer, Italy
Medium voltage transformer, PolandShell type transformer with DUO cores, Russia
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3-phase choke, Italy
7.5 MVA transformer, South Africa
Examples of voltage transformers
Example of frame
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Marine transformer, Norway
6.3 kVA transformer, Russia
75 kVA oil distribution transformer, Macedonia
Three phase 100 kVA transformer, Poland
100 kVA transformer, Czech Republic
40 kVA transformer with NOSS core, Turkey
4-core 5-limb 3-ph transformer, Australia
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2 kVA transformer with Stepbutt core
DUO transformer used for vacuum tube amplifier20 kVA transformerwith DG core, Slovakia
Australia & New ZealandABB Australia, Darra, AustraliaAEM Cores Pty, Ltd, Gillman, AustraliaETEL Distribution Transformers, Auckland, New ZealandThycon, Coburg, AustraliaTyree Transformers, Mittagong, Australia
AsiaAlfa Transformers, Vadodara, IndiaETAH SDN. BHD., Kuala Lumpur, MalaysiaJupiter Electricals, Vadodara, IndiaHan Chang Trans Co, Busan, KoreaKotsons, Agra, IndiaKRYFS Power Components, Mumbai, IndiaMangal Electrical Industries, Jaipur, IndiaManu Power Equipments Pvt, Ltd. Hyderabad, IndiaNeptune Stampings, Vadodara, IndiaPatson Transformers, Gujarat, IndiaSangrur Industrial Corp, Sangrur, IndiaShirdi Sai Laminations, Kadapa, IndiaStar Delta Transformers, Shopal, IndiaUniversal Electro Magnetic Cores, Kadapa, IndiaUttam Electricals Ltd., Jaipur, India
AfricaAlloy Magnetic Cores, Elsburg, South AfricaAreva, Johannesburg, South AfricaEgytrafo, Heliopolis, Egypt
Middle EastFederal Transformers, Abu Dhabi, U. A. E.
North AmericaABB Inc, Jefferson City, Missouri, USAAmbar Electroingenieria, Ecatepec, MexicoBCL Magnetics, Burlington, Ontario, CanadaCarte International, Winnipeg, CanadaCentral Moloney Inc., Pine Bluff, Arizona, USACondumex, Laredo, MexicoCorMag, Burlington, Ontario, CanadaEaton Electrical, Arden, North Carolina, USAEl-Met-Parts, Dundas, Ontario, CanadaElectromagnetic Ind., Clearwater, Florida, USAInstrument Transformers, Clearwater, Florida, USAKuhlman Electric Corp., Versailles, Kentucky, USALakeView Metals Inc., Winthrop Harbor, Illinois, USAMagnetic Metals, Anaheim, California, USAPauwels Transformers, Missouri, USAPhasetronics, Clearwater, Florida, USAPower Magnetics, Gardena, California, USAProlec GE, Apodaca, MexicoTC Metals, City of Commerce, California, USA
South AmericaCaivet Transformadores, Caracas, VenezuelaCNS, Sao Paulo, BrazilCorporacion Iadiexport, VenezuelaEcuatran SA, Ambato, EcuadorFrana International Ltda., Bogota, ColombiaINATRA, Guyaquil, EcuadorRhona S.A., Vina Del Mar, ChileRymel Engenieria Electrica, Itaqui-Autoquia, ColombiaSiemens, Bogota, Colombia
S O M E R E F E R E N C E S
AEM Cores Pty. Ltd.95B Bedford Street, GillmanSA 5013, AustraliaTel.: +61 8 8341 0086Fax: +61 8 8341 [email protected]
UNICORE EUROPETyršova 1033, 744 01 Frenštát p. R.Czech RepublicTel.: +420 608 834 [email protected]
Austria, Germany & SwitzerlandSchäppi IndustrievertretungenGeissweidli 5CH-8846 WillerzellTel./Fax: ++41 55 422 00 40Tel.: ++41 79 620 35 [email protected]
Denmark & SwedenNIKATEK ApSKirke Værløsevej 223500 VærløseTel.: +45 4448 3211Fax: +45 4448 [email protected]
Agents in Europe
RussiaTC WindeqDomodedovskoe shosse, 1/3Moscow 142116Tel.: ++79 261 939 494Tel.: ++79 263 789 [email protected]
GreeceKalivis Electromechanica S.A.55 Orfeos St.Athens 11854Tel: +30-2103421547Fax: [email protected]
SpainComercial Elosil, S.L. P.I. Rosanes C/Alemania, 34 08769 Castellvi De RosanesTel.: +34 93 775 10 [email protected]
TurkeyUYGAR Teknoloji MühendislikElektrik MakineleriSan. ve Tic. Ltd. Sti.1420 Sokak No: 30/1-135220 Kahramanlar-IzmirTel.: ++90 232 445 51 62Fax: ++90 232 445 51 [email protected]
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ting:
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Cruciform 630 kVA DUO2 core from 8 strips
Technical Consultant for Cast Resin and Oil type Distribution TransformerDuo Core Transformer Design and ApplicationMr. Ergin Dikmen, Turkey, [email protected]
HungaryEXIMTRADE Ltd.Csengery u. 531067 BudapestTel.: ++36+1 302-1307Fax: ++36+1 [email protected]
BeneluxWescap BVSlagenkampweg 37731 TK OmmenTel.: +31 (0) 529 46 28 30Fax: +31 (0) 529 46 31 [email protected]
