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What Are the Features of Amorphous Core Transformers?

What Are the Features of Amorphous Core Transformers?

2022-11-29

Amorphous core transformers are composed of thin sheets of ferromagnetic amorphous metal. Because of their stronger resistance and smaller foils, they have better efficiency and high-frequency wave resistance. Amorphous core transformers contribute significantly to the reduction of no-load inefficiencies.

Amorphous core transformers increase electrical power distribution efficiency by lowering transformer core losses. These productivity increases lead to less energy production, associated with lower carbon emissions of ecologically sensitive gases such as SO2, CO2, and others; the net cost of utilities also decreases.


What is Amorphous Core Transformer?

The cores of typical transformers are composed of arrays of silicon steel laminations with a virtually homogeneous crystalline structure (CRGO). A steel ribbon is a spiral to create the core of transformers with amorphous cores.

Amorphous core transformers have a significant advantage in that amorphous steel has reduced hysteresis losses. Briefly, lower energy is wasted as heat during core magnetization and de-magnetization.


What exactly is Amorphous C Core?

Metallic glass materials with no crystalline structure make amorphous c cores (amorphous cut cores), as seen in silicon steels and nanocrystalline cores. Because amorphous atomic structures have substantially greater resistivity than crystalline alloys, amorphous c cores provide outstanding frequency sensitivity and efficiency.

Amorphous c cores provide a more extensive working temperature range, far higher flux capacity, and significantly higher impedance at high frequencies than ferrite cores. Amorphous c cores are robust in tension as well as compression. They are resilient to cracking and rust.

Amorphous Core Application

Because of their minimal core loss, amorphous cores are commonly employed in electrical power systems, including power transformers and inductive instruments. It features an attractive ferromagnetic formless metal alloyed core.

This steel mesh is coiled to produce the transformer's core. Moreover, amorphous core transformers use a material with high attractive vulnerability, poor connectivity, and high electrical resistance.


1. Technological Benefit

Amorphous metal cores can function at 1.56 Tesla, whereas ordinary ferrite cores can only run up to a flux saturation level (BSAT) of 0.49 Tesla. When combined with the permeability of high-end ferrites and the capacity to produce substantial core sizes, these cores can be an excellent choice for several of these elements.

For several EMC applications, nanocrystalline amorphous metal provides size, component, and effort saving.


2. Microlite 100μ

These cores are perfect for PFC boost inductor applications with power distribution intervals varying from 300 to 6kW.

· Microlite 100 are tape-wrapped amorphous toroidal cores with a narrow gap that attain permeabilities below 245.

· The alloy is temperature consistent across a broad range of temperatures and has fewer and smaller gaps than comparable E-core ferrites.

· The smaller and fewer gaps lessen EMC problems from fringing flux and stray field.

· Most designs may be built with fewer turns and reduced losses, resulting in a smaller, more cost-effective design.

· In some instances, these cores may be a viable replacement for differential input inductors and SMPS output inductors.


3. C-cores from Powerlite

These amorphous cores coiled in a C-core form are perfect for AC reactors and DC inductors with current values varying from 10 to 1000 amps. The C-core also supports single and triple-phase transformer layouts.

Triple-phase designs are possible using typical single-phase cores, or a bespoke triple-phase core can be created in two sequences, as demonstrated below:

· Amorphous metal C-cores operate at a higher frequency while maintaining the same flux level. On the other hand, standard steel cores work at lower flux density rates as the frequency rates gets higher.

· Significantly more material is required to compensate for running at lower flux densities.

· Despite the additional material, greater temperatures arise. The I2R of the winding is another factor that contributes to lesser losses.

· A smaller, lighter amorphous core decreases your mean length per turn, resulting in fewer I2R power loss and lower copper prices.


4. Winding Options

Regarding higher current applications, such cores provide alternative ways for the conductor wrapping technique that toroidally formed cores do not provide:

· The copper foil

· Edge or disc winding on prominent and significant gauge square conductors.

Winding can be done on a separate mandrel in each of the possibilities mentioned above and then assembled onto the C-core following the winding process. Litz is a type of wire widely used in higher electrical frequency circuits. On the other hand, terminating Litz wire for these applications can be costly. Disc or edge winding is another option to explore.

Higher wattage power switches with signal frequencies of 10 and 20kHz are now affordable to the more excellent power developer. Yet, this can produce higher temperatures and significantly bigger core sizes than a comparable amorphous core tech.


Amorphous Core Elements

The remarkable aspects of the amorphous core that are distinguishing qualities will be addressed further below.


1. High Magnetic Susceptibility/Electrical Resistance and Low Coercivity

The core material's electrical resistance and magnetic susceptibility are all high except for coercivity. Moreover, low losses are caused by high resistance and thin foils. Amorphous cores, on the other hand, have a lower saturation induction.


2. Durability

The Amorphous Core has a solid and robust structure. They may make it in several methods, including fast cooling from a molten state.


3. Smart Safety

Technological advancements in electrification have resulted in increased efficiency in a wide range of new market solutions. With high flux density and low coercivity, existing core magnetic materials frequently struggle to dissipate less power.


Amorphous Core Transformer Benefits

· Losses are decreased by 70% as compared to a standard grade.

· Reduced hysteresis and eddy current losses are owing to increased magnetic permeability and low raw material thickness.

· Improved overload endurance because heat production is reduced due to lesser copper loss.

· Ecological favorable decreases Emissions of co2 owing to decreased generation requirement. And the low overall cost of ownership.

· It enhanced short circuit strength as a result of the spiral structure.

· The core coil assembly is simple to construct and repair.


Final Thoughts

Amorphous core transformers offer several prominent features over regular CRGO transformers. The amorphous core has good magnetic and mechanical characteristics, solid electrical resistivity, and electromechanical characteristics.


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