As a leader in the high efficiency electrical transformer core market, it’s safe to say that we here at Corefficient know a thing or two about how to create a reliable end product. In past blog posts, we’ve covered the interesting history behind the electrical transformer core, and this week, we’re going to cover how an electrical transformer core is made; the Coreffiicent way.
STEP 1: The Material
Before one can even begin the electrical transformer core construction process, you need to make sure that you’re using the best materials available. The material of choice for electrical transformer core companies is cold rolled grain oriented electrical steel, and Corefficient is no exception.
Corefficient has extensive on-site testing capabilities to ensure that the material we receive from our suppliers has exceptional magnetic flux and permeability properties. Why go through the trouble? It’s simple – the better the material, the easier it will be for the magnetic field of the core to flow. Also, high quality cold rolled grain oriented electrical steel reduces losses by reducing the strength of the eddy current.
STEP 2: Material Prep
Now that we’ve ascertained that we’re working with superior quality material, it’s time to cut the material for construction. For our Step Lap Full MITRE Cores, we make use of top of the line GEORG brand TBA lines for the cutting of electrical steel. For our wound cores, we use our highly versatile TRANCO and AEM machines, allowing us to work closely with our customers and their unique specifications for their core. These fully automated precision cutting lines allow us to complete our construction process with incredible speed.
STEP 3: Assembly
Next stop on the assembly line, we stack the core using our fully automated machine. Within 15-20 minutes, we have full stacks of electrical steel that are ready to be shipped as logs, or further assembled into fully functional transformers. With our Step Lap Full MITRE Cores, they’re moved down the assembly line, where our team performs a series of tests and quality checks including testing on a Yokogawa precision power analyzer.
For our DISTRIBUTED GAP Cores, we offer core annealing services, where we utilize our continuously fed SECO/WARWICK annealing furnace first, through annealing, the transformer cores’ magnetic properties are restored. Second, our core annealing services strive to reduce carbon levels within electrical steel to levels less than .01%. Our core annealing process is proven to increase strength, formability and elasticity to the electrical transformer core.
Step 4: Delivery
Finally, once your core is complete to your specifications, we ship it off. Corefficient is proud of our 100% SOT (Ship on Time) record, and our customers receive their finished core within two weeks of completion.
Video: There’s a misconception in the industry that in receiving a fully assembled core, that having to remove and add in the top yoke has an effect on core losses in the transformer core – increasing the destruction factor of the transformer core. Corefficient has proven through our own testing and evaluation that this is not the case. We’ve removed and added in top yokes after our “drop and top process,” determining that there’s little to no effect on core performance.