The Crucial Role of Iron Cores in Transformer Design and Function

The iron core serves a crucial role in the magnetic circuit of transformers, acting as its structural framework. Its design and manufacturing significantly influence various aspects of transformer performance, including losses, noise levels, insulation strength, and susceptibility to short circuits.

During the manufacturing process, strict adherence to detailed drawings, standards, and procedures is essential. Live parts must be securely interconnected, and grounding points must maintain excellent contact to ensure operational reliability.

Core Clamp Requirements

• Sufficient Strength: Ensuring robustness to withstand mechanical stresses.
• Welding Wire Strength: Using welding materials that meet strength specifications.
• Processing Accuracy: Precision in manufacturing to maintain dimensional integrity.
• No “Bag” at Welding Points: Ensuring weld integrity without voids or defects.
• Vertical Limbs: Proper alignment of core limbs perpendicular to the base.
• Vertical Center Line: Alignment of pressure pin nut centerline perpendicular to core limbs after welding.
• Planarity of Limbs: Ensuring limbs lie on the same horizontal plane under both high and low pressure, particularly at ends A and C.
• Single Pass Nut Engagement: Nut threading with a three-cone pass.
• Unpainted Contact Areas: Ensuring non-painted surfaces for reliable electrical contact.
• Chamfered Clamps: Chamfering edges of clamps to prevent sharp corners.

Key Points of the Core Stacking Process

• Preparation: Gathering necessary tools and materials including clamps, insulation, sleepers, beams, pull plates, pressure pins, and foot insulation.
• Stack Placement: Place the core on a hydraulic lifting platform ensuring alignment with the center.
• Platform Leveling: Ensuring the platform is leveled to maintain core center alignment.
• Jack Placement: Positioning jacks with adequate space for pull straps and clamps.
• Fixing Jacks: Securing jacks firmly on the platform.
• Insulation and Alignment: Ensuring insulation and clamps are aligned horizontally.
• Layer Stacking: Sequentially stacking and measuring each layer for dimensional accuracy.
• Nailing Frequency: Nailing every 5mm for structural integrity.
• Tolerance Management: Compensating for tolerance variations between layers.
• Oil Channel Installation: Implementing oil channels as per design specifications.
• Support Plate Placement: Ensuring proper placement of support plates.
• Verticality Check: Verifying vertical alignment at each level.
• Final Assembly: Installing crossbeams, tie straps, and equal thickness pads to prevent deformation and reduce losses.
• Cleaning Debris: Removing debris to maintain cleanliness.
• Tensioning Straps: Securing core and platform with tensioning straps.
• Insulation Resistance Check: Verifying insulation resistance post-assembly.

Grounding and Safety

• The core must be grounded at a single point to maintain electrical safety.
• Ensuring all metal parts connected to the core are at zero potential to prevent electrical hazards.
• Avoid dual-point grounding to prevent potential short circuits and associated risks of current flow and equipment damage.

By meticulously adhering to these procedures and standards, manufacturers ensure transformers meet operational requirements while maintaining safety and reliability in electrical systems.

The Daelim Transformer utilizes high-quality silicon steel sheets as core materials and adheres rigorously to key points in the core stacking process. This commitment ensures that the Transformers produced exhibit low losses, minimal partial discharge, reduced noise levels, enhanced short-circuit resistance, and superior insulation performance. These transformers provide sustainable and efficient power solutions for a variety of industrial and commercial applications.