The transformer iron core is the core component of a transformer’s magnetic circuit, guiding and concentrating magnetic flux to achieve efficient magnetic coupling and energy transfer between windings. High-permeability core materials, such as cold-rolled grain-oriented silicon steel sheets, significantly reduce magnetic reluctance, thereby lowering no-load losses and improving transformer efficiency.

Manufacturing Process

Lamination Cutting: Automated cutting machines precisely cut silicon steel sheets to the required dimensions and miter angles (e.g., 45°).

Annealing and Stress Relief: Cut laminations undergo hydrogen-atmosphere annealing to remove processing stress and restore magnetic properties.

Stacking and Jointing: Common stacking methods include butt-lap, step-lap, and mitered joint, each with its own advantages; step-lap stacking notably reduces local saturation and losses.

Clamping and Curing: Specialized fixtures clamp the core stack, and the varnish or adhesive is cured under heat to ensure tight, stable lamination bonding.

Performance Advantages

Low No-Load Loss: The combination of CRGO material and precise stacking minimizes iron losses, supporting energy savings and emission reductions.

Noise and Vibration Reduction: Miter joints and inter-laminar bonding techniques suppress lamination vibration, significantly lowering operational noise.

High Magnetic Saturation: Annealed silicon steel offers higher saturation flux density, accommodating high-power, large-current applications.

Excellent Thermal Stability: Protective coatings isolate moisture and oxidation, enhancing mechanical strength and extending service life.

Quality Inspection and Standards

No-Load Loss Testing: Measures transformer core losses under specified voltage to ensure compliance with international standards (e.g., ISO9001, ISO14001 and ISO45001).

Permeability and Hysteresis Loop Testing: Validates that silicon steel sheets meet performance specifications.

Vibration and Noise Testing: Assesses vibration amplitude and noise levels under standard voltage and frequency for operational comfort.

Inter-Laminar Bonding and Insulation Testing: Examines varnish or adhesive curing quality and inter-laminar insulation withstand voltage to guarantee long-term reliability.

Main Application Scenarios

Power Distribution and Substations: Transformer core components of medium- and low-voltage distribution transformers in power transmission networks.

Industrial Motors and Furnaces: High-power, large-current applications such as induction heating and welding equipment rely on high-performance transformer iron cores for precise control.

Rail Transit and New Energy: Applications like traction transformers and photovoltaic inverters demand cores with superior efficiency and reliability.

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