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    Cores of magnetic circuits

    make a very important part for transformers production... Cores of magnetic circuits
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    Toroidal Cores

    Toroidal core is basically wounded grain oriented silicon strip containing approximately 3% of silicium to the circle or other form.. Toroidal Cores
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    Cut C Cores

    Wound transformer cores are manufactured in process of winding up the transformer strip on a mandrel followed by the processes.. Cut C Cores
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    Unicore cores

    UNICORE constitute a new line of cores of magnetic circuits. Unicore cores

Unicore Cores

→  UNCUT UNICORE
→  DUO UNICORE
→  BUTT UNICORE
→  STEP BUTT UNICORE
→  COMBI STEP BUTT UNICORE
→  DGAP CORES
→  CRUICY FORM UNICORE

UNICORE constitute a new line of cores of magnetic circuits. The manufacturing technology was developed in 1997 and its aim was to simplify the existing technology and improvement of parameters of electrical machines. Due to advantages of their construction UNICORE are apt to replace almost all conventional C cores.

UNICORE advanced technology leads to low specific losses. Their construction is simplified – they don’t have to pass through the time and cost consuming production process which contributes to very favorable price and short delivery time. At assembly the existing types of coil forms can be kept therefore there are no changes in transformer construction needed.

BENEFITS OF UNICORE

▪ Low specific losses
▪ Easy assembly
▪ Favorable price
▪ Saving in quantity of used copper
▪ The banding of cores is not necessary
▪ Short delivery time

Specific losses

UNICORE sums up all advantages of C cores, but their specific losses are lower by 20 - 40%. Therefore it is possible to economy in the magnetic circuit weight and amount of cooper used. We have tested the conventional cut core of C 31002 type (core cross-section 12 cm2, Ls = 36.3 cm and weight = 3.10 kg) and UNICORE - DUO2 and DUO3 cores of the same cross-section and medium-length. Comparison of results can be found in the chart hereunder.

 

Core type Finish Heff
A/m
Bmax.
T
Specific losses
W/kg
Input
VA/kg
C 31002 (3,10 kg) annealed 110 1,50 1,20 5,10
260 1,70 1,85 13,90
C 31002 - DUO 02 UNICORE unanealed 140 1,50 1,30 6,50
370 1,70 1,80 19,50
annealed 45 1,50 0,95 1,90
150 1,70 1,45 7,30
C 31002 - DUO 03 UNICORE unanealed 150 1,50 1,40 7,50
450 1,70; 1,95 24,00
annealed 60 1,50 1,00 2,10
240 1,70 1,55 12,00

 

FUNDAMENTAL TYPES AND SIZES OF UNICORE CORES

UNICORE have been developed to replace conventional C cores. The only limitation factors are necessary minimum dimensions of the inner section (see chart). During assembly the existing types of bobbins can be used therefore there are no changes in magnetic circuit construction needed.

Cores can be supplied with annealed or unanealed finish. Subsequent annealing of cores decreases losses by 10 to 30 % depending on the core size.

Drawing

The core angle of a UNICORE can be either 30°, 45° or 90° depending on their use by the electrical machines producer.

The core’s parting line can be
- straight as at the conventional C core (BUTT) or
- with stepped cuts along one or two legs (e.g. DUO)
.

To specify your core request you need to know the inner section dimension, band thickness and width, thickness of wounded layer, corner angle, core type and required material quality of the core.

Dimension Minimum (mm) Maximum (mm)
Inner section length80unlimited *
Inner section width40unlimited *
Band width20300
Coiled layerBand thicknessunlimited *

* Dimension is not restricted by manufacturing tools potential, only by practical reasons


UNCUT UNICORE

Due to advantages of their construction UNCUT UNICORES are apt to replace almost all conventional uncut C cores and rectangular toroidal cores.

Corner angle may be 45 or 90 degrees.

Application possibilities of UNCUT cores

▪ rectangular current transformers
▪ voltage transformers

Drawing

 

DUO UNICORE

DUO core that can replace conventional C cores. Due to its low specific losses it allows better output parameters of final magnetic circuit. Low losses can be reached as a result of air gaps layout along the core leg.

DUO core has been developed to facilitate and accelerate cores assembly into 1 or 2 bobbins. It consists of two gradually divided halves – male and female – which gradually assemble into bobbins (bobbin). The inner lamination runs around the full circumference of the core and the last outer extended lamination functions also as tightening strap. The last lamination (TIG) is welded on the core which fixates the core perfectly.

Photo DUO2 core, one-phased – prior to assembly into a bobbins.
(male part on the left / female part on the right)

 

Application possibilities of DUO cores

▪ single-phase transformers
▪ three-phase transformers

 

Single-phase DUO core

Drawing

 

Three-phase DUO core

Drawing

 

DUO Unicore types of construction

Drawing DUO 1
▪ One lamination in one layer
▪ The lowest losses – relatively longer assembly of the core into coils
Drawing DUO 2
▪ Two laminations in one layer
▪ Combination between lowest losses and shortest assembly time
Drawing DUO 3
▪ Three laminations per layer
▪ Relatively higher losses
▪ Fast core assembly into coils

BENEFITS OF DUO CORES

▪ Easy assembly
▪ Low core losses
▪ Savings in core weight
▪ Saving in quantity of used copper
▪ No tightening straps necessary

 

BUTT UNICORE

BUTT is a core suitable for chokes; its front surface is superposed thus enabling conventional C cores replacement. Individual layers are formed to create an even surface of the core column. The corner angle can be set to 45° or 90°, its radius is also possible to set.

Application possibilities of BUTT cores
▪ single-phase chokes
▪ three-phase chokes

 

BUTT Unicore types of construction

BUTT 2
▪ Single-phase core

Drawing

 

BUTT 3
▪ Three-phase core

Drawing

 

BENEFITS OF BUTT CORES

▪ Easier assembly than conventional C cores
▪ Significantly lower price than conventional C core
▪ It is possible to add the last full lamination for welding of TIG by welding machine – functions as a tightening strap

 

STEP BUTT UNICORE

Step Butt Unicore belongs to the group of BUTT Unicore. The gap is designed as steps.

Step Butt Unicores can be annealed to reduce loss and make assembly easier.

Application possibilities of STEP BUTT cores

▪ transformers up to approximately 1 KVA

 

Drawing

 

BENEFITS OF STEP BUTT CORES

▪ Lower core losses than comparable C cores
▪ Higher transformer output
▪ Lower transformer weight

 

Step Butt Orthogonal Diagram

Drawing

 

COMBI STEP BUTT UNICORE

Combi Step Butt Unicore also belongs to the group of STEP BUTT Unicore. The gaps are on the opposite sides of the core. So the gap is on every other packet in the one leg. Thanks to this we can achieve reduction of losses and noise.

Drawing

 

DGAP CORES

Diving gap of DGAP core is layed out around one core leg. This solution brings the lowest specific losses and very low level of magnetizing current. It makes them ideal for low loss applications. The DGAP core characteristics are very similar to those of a toroidal core.

Application possibilities of DGAP cores

▪ transformers bigger than 1kVA
LOW LOSS APPLICATIONS
▪ single-phase and three-phase distribution transformers

 

Drawing

 

The position and specification of each DG face can be easily and accurately specified to best suit your application.

BENEFITS OF DGAP CORES

▪ The lowest core losses
▪ Higher transformer output
▪ Lower transformer weight
▪ Saving in quantity of used copper

 

Photo

 

CRUICY FORM UNICORE

All above mentioned types of UNICORE we are capable to manufacture in cruicy form. This means you can get all advantages of UNICORE even if your transformers are made of cruicy form C-cores.

 

Drawing

 

Photo

 

Photo

 

WE SHALL BE GLAD TO PROVIDE DETAILED INFORMATION, SUPPLY CORES SAMPLES, PROJECT, PRODUCE AND SUPPLY TRANSFORMER FRAMES AND TRAIN YOUR EMPLOYEES IN CORES ASSEMBLY INTO BOBBINS.