The 3D wound core transformer boasts outstanding energy-saving performance and distinct structural advantages. After more than a decade of research and development, 3D wound core transformers manufactured in China exhibit a rational structural design. Compared with traditional laminated core transformers, these transformers offer numerous benefits, including energy efficiency, material savings, reduced noise, and stable performance.
The no-load loss of amorphous alloy transformers is only half that of S13 silicon steel 3D wound core distribution transformers, further enhancing their energy-saving capability.
Structural and Manufacturing Differences
The 3D wound core differs significantly in structure and manufacturing process from laminated cores and flat wound cores. Despite having the same cross-sectional area for the core limbs, window height, and core limb center distance, the structural and functional differences are substantial.
What is an Amorphous 3D Wound Core Transformer?
A 3D wound core is a type of wound core. The entire core is assembled from three identical single-frame components to form an equilateral triangular 3D structure. This structure provides excellent stability, high mechanical strength, and consistent stress distribution across the three phases, enhancing the short-circuit resistance of the transformer. The core’s three limbs are arranged in an equilateral triangular 3D layout.
Existing amorphous alloy transformer core designs primarily follow two configurations:
Four-frame five-limb design
Three-frame three-limb design
Both use open flat wound cores with rectangular cross-sections for the core limbs and coils, mainly because amorphous alloy core limbs are rectangular in shape.
However, the rectangular cross-sections of the core limbs and coils reduce resistance to sudden short circuits. Structural reinforcements and compression techniques are required to address this issue. Additionally, flat wound core designs involve multiple joints, increasing noise levels.
While these problems can be mitigated through additional raw materials and structural reinforcements, the increased costs negatively impact the widespread adoption of amorphous alloy transformers.
Advantages of 3D Wound Core Transformers
3D wound core transformers provide:
Lower noise levels
Enhanced resistance to sudden short circuits
Reduced size and weight of the transformer
Lower production and operational cost
Future Prospects
Developing amorphous alloy 3D wound core transformers that integrate the advantages of the aforementioned designs offers broad application potential and significant socioeconomic benefits. This innovation addresses key limitations of existing transformer designs, paving the way for improved performance and widespread use in energy systems.