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Tridimensional CRGO core transformer

Tridimensional CRGO core transformer Tridimensional CRGO core transformer Tridimensional CRGO core transformer Tridimensional CRGO core transformer
Product name:Tridimensional CRGO core transformer
Item:9-5
Details:
 
I Description
Tridimensional wrapped CRGO core transformer is a new high performance transformer with more reasonable structure, better performance, less production cost.
The tridimensional wrapped CRGO core like a new innovation, comparing to conventional tranformers, it changes magnetics structure, drastically depresses no-load loss, no-load current and noise level. And thus reduce transformer’s running cost.

II Structure of tridimensional wrapped core
2.1 This tri-dimensional wrapped core is comprised of three cores which are exactly same!
top view of 3D core Real photo of single core Section of single core


2.2 Section of the three columns is round and lamination factor reaches 99%


III Technology specialties
3.1 Wrapped core, no joints

Each single core of this tridimensional wrapped core is wrapped from very long CRGO strips and so magnetic circuits distribute even in each position, avoiding to form high resistance area because of laminating joints, and avoiding magnetic flux density distort at joining positions.

3.2 After wrapped, core is annealed
During slitting and wrapping, because of stretching and magnetic allision, performance of CRGO is effected too much. After annealed in vacuum annealing furnace, magnetic performance is recovered. Also high temperature annealing can eliminate the innerstree occurred during wrapping.

3.3 Tridimensional wrapped core doesn’t need clamping tools
Stacking factor of the wrapped core itself reaches 98% and the tridimensional core only need to be bounded by insulation tape during assembly, no need steel clamping tools which may worsen core performance.



3.4 High mechanical automation, few human factors

The whole production progress of tridimensional wrapped core, from CRGO strip slitting, diagonal slitting to wrapping and annealing, is finished by machines automatically, very few human factors.

IV Characteristics of the tridimensional cores

4.1 Optimized magnetic circuit structure
Magnetic circuits of each phase are completely symmetrical; circuit length is completely same and the sum of total length is the shortest (comparing to any other core structure); No-load current of each phase is completely balanced, and the third harmonic will not be occurred.

4.2 Drepressing no-load loss, no-load current and noise level drastically
There are no joints between interlamination; Magnetic flow direction is completely same to grain orientation of CRGO; And the core will be annealed.

4.3 Unique natural ventilation and radiation
The three yoke blocks are in 60 degree to each other. After adding coils, a natural “drawn chimney” is formed. Temperature difference between yoke upper and lower sections is about 30-40℃ and there will be air convection inside the “drawn chimney” which will radiate the heat very quickly. Thus it depresses the temperature raising of transformer and raises over-load capacity of transformer.

4.4 Compact structure, saving material and space
Section of the core column is round, min. diameter and so the three phase windings are more compact, saving copper materials and reducing transformer sizes.

4.5 Theft deterrent:
3D wound core is a whole body, can’t be dismantled and coils can’t be removed. And whole weight of one 200kVA transformer is 650kg.

V Comparation between tridimensional core and conventional laminated core (under same CRGO material, same column section area, same window height, same central distance between columns)

5.1 CRGO material saved

1) Weight of 3D core is about 10-15% lighter than laminated core
2) Material waste during processing: 3D core than that of laminated core

5.2 Copper coil material is saved about 2~3% less than that of laminated core

5.3 No-load loss and no-load current are less
1) No-load loss is 30% less
2) No-load current is 70% less

5.4 Noise level is reduced about 7~10 dB.

5.5 Three-phase balance: 3D core is three-phase balanced completely. For laminated core, magnetic circuit length of two side columns is 20% more than that of the middle column
.

VI Comparation between tridimensional wrapped core and plane wrapped core (under same CRGO material, same column section area, same window height, same central distance between columns)

6.1 CRGO material is saved: weight is 15% less

6.2 No-load loss is about 10% less (because flux density of 3D core is 15.5% more than that of plane wrapped core)

6.3 Three-phase balance: plane wrapped core is worse


VII Relative Machines

7.1 Diagonal slitting machine, about USD 85000.

7.2 Core winding machine, about USD 55000.

7.3 Annealing furnace, about USD 82000.

7.4 Coil winding machine, about USD 19000.

7.5 Foil coil winding machine, about USD 85000

7.6 Vacuum casting machine (for dry-try transformer, about USD 100,000)

7.7 Transformer coil drying oven (for dry-type transformer, about USD 30,000)

VIII Attached Tables

Table 1: Main Performance of S9, S11, S13 Oil-immersed Transformer

Capacity

(KVA)

No-load Loss (W)

With-load Loss (W)

No-load Current (%)

Short-circuit resistant %

S9

S11

S13

S9,S11

S13

Lam. Core

S13 3D core

30

130

100

80

600

600

2.1

0.26

4.0

50

170

130

100

870

870

2

0.24

63

200

150

110

1040

1040

1.9

0.23

80

250

180

130

1250

1250

1.8

0.22

100

290

200

150

1500

1500

1.6

0.21

125

340

240

170

1800

1800

1.5

0.20

160

400

280

200

2200

2200

1.4

0.19

200

480

340

240

2600

2600

1.3

0.18

250

560

400

290

3050

3050

1.2

0.17

315

670

480

340

3650

3650

1.1

0.16

400

800

570

410

4300

4300

1.0

0.16

500

960

680

480

5150

5150

1.0

0.16

630

1200

810

570

6200

6200

1.0

0.15

4.5

800

1400

980

700

7500

7500

1.0

0.15

1000

1700

1150

830

10300

10300

0.7

0.14

1250

1950

1360

970

12000

12000

0.6

0.13

1600

2400

1640

1170

14500

14500

0.6

0.12


Note: Tridimensional wrapped core transformer can reach S13 standard!

 

Table 2: Main Performance of S9, S11, S13 Dry-type Transformer

Capacity

(KVA)

No-load Loss (W)

Load Loss (W, @75)

No-load Current (%)

Imp.

%

S9

S10

S11

S13

S9

S10,S11,S13

S9

S10,S11

S13

30

220

190

170

130

650

620

2.4

0.6

0.6

4.0

50

310

270

240

190

920

870

2.4

0.6

0.6

80

420

370

330

260

1270

1205

1.8

0.6

0.6

100

450

400

260

280

1460

1370

1.8

0.6

0.5

125

530

470

420

330

1710

1620

1.6

0.6

0.5

160

610

540

480

380

1960

1860

1.6

0.6

0.4

200

700

620

550

440

2340

2210

1.4

0.5

0.4

250

810

720

640

510

2550

2410

1.4

0.5

0.35

315

990

880

790

630

3200

3030

1.2

0.5

0.35

400

1100

980

880

700

3680

3480

1.2

0.4

0.3

500

1310

1160

1040

830

4510

4260

1.2

0.4

0.3

630

1460

1300

1170

930

5510

5200

1.0

0.3

0.25

6.0

800

1710

1520

1360

1080

6430

6080

1.0

0.3

0.25

1000

1990

1770

1590

1270

7520

7100

1.0

0.3

0.2

1250

2350

2090

1880

1500

8960

8460

1.0

0.25

0.2

1600

2760

2450

2200

1760

10830

10240

1.0

0.25

0.18

2000

3400

3050

2740

2190

13360

12620

0.8

0.2

0.18

2500

4000

3600

3240

2590

15870

14990

0.8

0.2

0.18

Note: 1. High voltage of above transformers are 6, 6.3, 10, 10.5, 11kV;

     2. Tap step: +/-5

     3. Output voltage: 0.4kV

     4. Vector group symbol: Dyn11, Yyn0

     5. Noise level:

Capacity (kVA)

30

50

80

100

125

160

200

250

315

Noise(dB)

45

45

45

45

45

45

45

45

45

Capacity (kVA)

400

500

630

800

1000

1250

1600

2000

2500

Noise (dB)

46

48

48

48

48

48

50

50

50

 

 

Table 3: Material Consumption of S13 National Standard Requirement

(copper, transformation ratio 10/0.4, +/-5%, Dyn11)

Capacity

Core

(kg)

Round copper wire

(kg)

Flat copper wire

(kg)

Oil

(kg)

Tank

(kg)

30/10

73

17.8

11.8

79

71

50/10

104

27

22.2

90

82

80/10

133

44.7

27.6

101

91

100/10

167

49.9

28.8

119

105

125/10

196

58.1

41.8

128

120

160/10

217

72.2

43.8

137

136

200/10

259

82.9

51.1

170

159

250/10

317

81

66.7

182

180

315/10

371

94.6

79.8

203

215

400/10

442

123.5

96

211

242

500/10

521

144.6

115

280

285

630/10

632

158.3

131.7

318

336

800/10

735

198.5

149.5

337

343

1000/10

851

231.8

152.4

505

516

1250/10

1037

259.2

158.8

543

615

1600/10

1250

336.6

194.9

558

682

 

 

Table 4: Compare Between 100kVA

Plane Wound Core & Tridimensional Wound Core

Core Type

Performance Level

CRGO code

Material used (kg)

No-load Loss

(W)

CRGO

Copper

Plane wound core

S11

DQ122G-30

165

172.3

200

Plane wound core

S11

3408 (Russian)

178

124

200

3D core

S11

3408 (Russian)

152

116

180

3D core

S13

23ZH100 (Japan)

151

115

149

 


 

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