AEM Unicore

Innovation in Transformer Cores and Manufacturing

Savings Transformers DUO assembly Other cores

Basic info

Unicore machine

DUO & DG core

References

October 2008

Basic information
History of the Unicore technology
AEM Cores Pty Ltd began operations in 1958 as a manufacturer of arc welders. Shortly after it began production of cut cores (C cores). From the 1970s AEM was the leader in specialist wound core manufacturing in Australia, producing single and three phase cut cores, toroidal cores in GOSS and Mumetal (NiFe) materials, and Distibuted Gap Cores. Today, AEM is the only specialist wound core manufacturer in South East Asia. Because the market being served is small and very demanding of special designs, AEM has for many years developed its own specialist machinery. During the late 1980s and early 1990s the high cost of manufacturing the labour intensive cut cores forced AEM to look for methods of increased automation. The philosophy of AEM, driven by the founder and owner, Bill Jenkinson, has always been to strive for greater and greater transformer efficiency through innovative core design. In the mid-1990s engineers at AEM produced prototype machinery to produce Unicores. The Unicore Technology was successfully used for some time by AEM and its customers before large core manufactures visiting from overseas saw it. They immediately wanted to buy the Unicore machine so that they could provide the advantages of Unicore products to their markets. More than 120 machines have been manufactured and Unicores are now being produced* or used in the following countries: Australia* Benelux Brasil* Canada* Chile* Colombia* Czech Republic* France India* Italy* Korea* Macedonia* Malaysia* Mexico* New Zealand* Norway Poland Russia* South Africa* Spain* Turkey* United Kingdom USA* Venezuela*

The latest development is the DUO core. It is a low loss Unicore designed for easy assembly. This core is expected to slowly replace the use of large E&I, strip laminations and C cores. We feel that ever tightening enviromental standards and efficiency requirements will drive the market towards high efficient Unicore poducts further in the future.

Advantages
The Unicore technology is very flexible, highly accurate, repeatable and reliable. Unlike production of toroidal and cut cores, it does not require any fixed tooling, such as various jigs and mandrils. Unicore laminations are fully formed when leaving the machine. For General Purpose Transformers, Unicores have lower losses than cut cores or E&I and 90 Cut Laminations. Core assembly is very fast. For Distribution Transformers, Unicore technology provides a highly flexible, accurate and reliable production system with all inherent advantages of wound core technology. Detail of DUO3

Basic info

Unicores
Similarly as toroidal or cut cores, Unicores belong to the family of wound magnetic cores. Historically there are more than ten different types of Unicores. Some of them are not used any more as they were replaced by better types. Unicores can be used for Distribution Transformers and General Purpose Transformers from less than 1000 VA to approx. 1500 kVA. According to latest knowledge a 10.000 kVA transformer has already been produced using our cores.

Materials for Unicores

Unicores can be produced from any grade of Grain Oriented Silicon Steel (GOSS) with thickness from 0.2 to 0.35 and strip width from 20 to 300 mm. Two strips can be run simutaneously when using less than 140 mm strip. It has been tested that some finer grades of GOSS can be also used for Unicores. For details please contact us.

Unicores can weigh up to 1500 kg. A Unicore is defined by the following parameters: Window Length (WL) Strip Width (SW) Strip Thickness (ST) Tightness Factor (TF) Window Width (WW) Build-up (BU) Corner Angle

Unicore faces can be straight butt, DUOcore, Distributed Gap or Uncut. Unicores can be produced with 30, 45 or 90 corners, depending on application. All these values can be easily specified and programmed. New Unicore types are continually developed.

Basic info

Unicore machine

DUO & DG core

DUO assembly

Other cores

Unicore geometry and sizes

Savings

Adjustable assembly plate

Transformers

References

The Unicore machine

Advantages
The Unicore machine is fully programmable computer controlled machinery. Therefore, it represents a very flexible production technology. Just by selecting a core type and entering core dimensions in the core definition file, one can easily produce a single core or a big volume of cores. Just-in-time production results in low level of inventory. No tooling is needed. AEM Australia

Power requirements
3 phase and neutral, 415 V AC, 50/60 Hz electric supply 6 kPa compressed air to drive the folder bar and lift the feed roller SAE 32 hydraulic oil to drive the guillotine

DUO core definition file

Unicore machine
Detail of machine operation

Electric and air supply, PC connection

Our European installations

More than 10 Unicore machines are operating in Europe now.

ALCE Elektrik, Turkey

VP Technotron, Czech Republic

Zucchiatti Elettromeccanica, Italy

Makitel, Macedonia Vakar, Czech Republic

Elesa Transformadores, Spain

INTEPS, Russia

Basic info

Unicore machine

DUO & DG core

DUO assembly

Other cores

Savings

Transformers

References

DUO core
Application
DUO core is the newest type of Unicore. It is a low loss, price competitive core with very easy assembly. It is used for core-type, single-leg and shell-type, single and 3-phase General Purpose Transformers. Annealed DUO cores with one lamination per overlap may be used for Distribution Transformers. After assembly into windings TIG welding of the last lamination and wedging is recommended. DUO3 core

DUO core types

To reduce assembly time, the number of laminations per overlap may be increased from 1 up to 3. Increasing from 1 to 2 results in a 45 % decrease in assembly time, and 2 to 3 results in a further 25 % decrease. Note that losses and magnetizing VA will increase.

DUO sizes
Dimension Window Length (WL) Window Width (WW) Strip Width (SW) Build Up (BU) Minimum (mm) 80 40 20 (with two strips) Material Thickness Maximum (mm) Unlimited* Unlimited* 300 (with one strip) Unlimited*

* Not limited by the Unicore machine. Limited only by practical transformer manufacturing considerations.

Material
Any grade of GOSS, thickness 0.2 to 0.35 mm.

Optional annealing
Annealing reduces losses by 10 to 30 %, depending on the core size.

DUO & DG core

No banding
Simple TIG weld of final lamination only.

DUO1 male half

3-ph DUO3 with corner holes

Distributed Gap cores

Application
DG Unicores represent a family of cores with a single cut per lamination. They are used for single-leg and shelltype, single and 3-phase Distribution Transformers. Unlike traditional technology of producing DG cores, no tooling is needed for production of DG Unicores.

DG Unicore types
There are several different types of DG Unicores, namely a core with straight cut face, Diverging face (cascade of cut faces fans out) and End-Overlap (spirally wound laminations) face. The position and specification of the DG face can be easily programmed.

DG Unicore size
Dimension Window Length (WL) Window Width (WW) Strip Width (SW) Build Up (BU)
*

Minimum (mm) 60 40 20 (with two strips) Material Thickness

Maximum (mm) Unlimited* Unlimited* 300 (with one strip) Unlimited*

Not limited by the Unicore machine. Limited only by practical transformer manufacturing considerations.

Material
Any grade of GOSS, thickness 0.2 to 0.35 mm.

End-Overlap type of DG core

Optional annealing
Annealing reduces losses by 10 to 30 % depending on the core size and is almost always desirable to achieve the highest efficiency.

40 kg single-phase DG core

3-ph DG core

Basic info

Unicore machine

DUO & DG core

DUO assembly

Other cores

Savings

Transformers

References

Single Phase DUO Core Assembly

Procedure
1. Insert the first full size inner lamination into the coils. 2. Insert the smallest male packet. 3. Insert the helper strips. 4. Insert the corresponding female packet and then remove the strips. 5. Now repeat the steps 2 to 4 until all packets including the last female half with the outer welding lamination have been inserted. 6. After welding the outer lamination an insulation material may be used to lightly wedge the remaining space between the core and the coil.

1 2 3 4 5 6

Example of a single phase DUO3 core assembly

Core size: WL 210, WW 60, SW 70, BU 60 mm Core weight: 21 kg Transformer power: 7.5 kVA Core production time: 18 min Core assembly time: max 4 min

DUO assembly

The disassembled core

Female half of the core

Male half of the core

Partly assembled core without bobbins

DUO3 detail Assembly plates

Taking a male packet

Taking a female packet

Three Phase DUO Core Assembly

Procedure
Assembly of a three phase DUO core is very similar to the single phase DUO assembly. Start with assembly of the first inner core into the coils. After the second inner core is assembled insert an insulation material to wedge the inner cores apart so that the first outer male packet fits accurately. Last lamination of the inner cores may be welded. Now insert the outer core.

Example of a Cast Resin Transformer

Core weight: 164 kg Core production time: 41 min Transformer power: 50 kVA Core assembly time: approx. 50 min

First inner core assembled

Inserting first lamination

Inserting female packet

Strapping the core

Wedging the inner cores

Start of outer core assembly

An assembly table

Source: EVPU, Slovakia

Basic info

Unicore machine

DUO & DG core

DUO assembly

Other cores

Savings

Transformers

References

Example of a 50 kVA oil distribution transformer

Core size (DUO3): WL 210, WW 105, SW 120, BU 84 mm Core weight: 110 kg Core production time: 38 min Core assembly time: approx. 40 min

DUO assembly
Source: Cotrafo, Italy

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Cruciform Unicores
25 kVA dry distribution transformer with DDG1 core
Core size (DDG): WL 280, WW 128, SW 60/90/120, BU 116 mm Core weight: 152 kg Core production time: approx. 70 min Core assembly time: approx. 60 min

100 kVA distribution transformer with DUO2 core

Core size: WL 345, WW 120, SW 55/75/105/120/135/145, BUP 138 Core weight: 284 kg Core assembly time: approx. 60 minutes

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Basic info

Unicore machine

DUO & DG core

DUO assembly

Other cores

Savings

Transformers

References

Other types of Unicores

Step Butt core
This type of Unicore is used for a shell type General Purpose Transformers only, up to approx. 1 kVA. Losses are much higher than DUO or DG cores but less than or comparable to a C core.

Replacement of laminations, 1600 VA

Other cores

Butt-2 and Butt-3 cores

These cores have a gap of programmable size in 2 (single phase) or 3 (3-phase) legs. They are used in chokes and reactors.

Butt-2 core from eight different strips

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Gapped core
It is a core with one gap of programmable size in one leg only.
WW

Demagnetizing ball bearings

Uncut core
It is a core with no cuts. The Unicore machine is only feeding and folding steel. Uncut cores are used for Current and Voltage Transformers. They are always annealed to achieve the lowest loss and magnetizing current.

Uncut core for Petersen coil

Straight laminations

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Basic info

Unicore machine

The Unicore machine can be programmed to produce rectangular 90 cut laminations which can be used for the manufacture of chokes and transformers.

DUO & DG core

DUO assembly

Other cores

Savings

WL

BU

Transformers

References

Savings with Unicore

Unicore Transformer
Core: Unicore DUO2 without annealing A Window: 155 60, Strip width: 90, Buildup: 50, Core weight: 20 kg B Window: 122 50, Strip width: 70, Buildup: 40, Core weight: 16,5 kg Technical parameters: A Induction: 1.4 T, Current density: 3.3 A/mm, No-load loss: 70 W B Induction: 1.3 T, Current density: 3.0 A/mm Dimensions: A Width 210 Depth 155 Height 270 B Width 260 Depth 160 Height 210 Total weight: A 31 kg B 26 kg

Savings

A Single Phase Transformer 5000 VA

B Three Phase Transformer 3000 VA

Classical Laminated Transformer

Dimensions: A Width 240 Depth 153 Height 310 B Width 264 Depth 132 Height 228 Total Weight: A 39 kg B 31 kg

Manual Magnetic

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Unicore production times

As a guide a MS Excel spreadsheet is offered. By entering dimensions, production time and weight of single and 3-phase DUO and DG cores are calculated. Loading two strips less than 140 mm wide doubles capacity of the machine.
Enter Core Dimensions WL 240 mm WW 80 mm SW 80 mm Strip Width is less than 130 mm, load two BUP 80 mm strips and double production ST 0,30 mm Note: The calculated cycle time is for one strip, loading two strips will halve the unit time and double production. Single Phase Cores min : sec Core Mass (Kg) Output (Kg/hr) DUO C core with 45deg corner 24:03 43 107 Distributed Gap (DGap, DDGap, EOLap) with 45deg corner 30deg corner Three Phase Cores DUO E core with 45 deg corner Distributed Gap (Ecore and Elap) with 45deg corner 30deg corner 21:43 27:54 min : sec 35:18 35:05 42:08 43 44 Core Mass (Kg) 69 69 70 119 95 Output (Kg/hr) 117 118 100 Unicore Production Times

Disclaimer: This spreadsheet is offered as a guide only, its accuracy cannot be guaranteed. Data is derived by graphical interpolation of empirical tests on actual cores made on a standard UCM2500 machine at AEM Cores Pty Ltd. Tightness Factor is assumed to be zero (default), increasing the TF will increase the core mass slightly. Dec03

Annealing Unicores
Unicores are fully formed by the machine. It means they do not have to be annealed if higher losses can be accepted. Depending on application, core size etc. one can decide that annealing is not necessary. With increasing size of a core the difference in losses between unannealled and annealed core is getting smaller.
DUO Core - Loss (W/kg) v Flux density (T)
2.2 2.0 1.8 1.6 1.4 1.2 1.0 0.8 0.6 0.4

Two different DUO cores - Loss (W/kg) v Flux density (T)

1.6

Loss (W/kg)

Loss (W/kg)

Core Type 1 Phase Window length = 119mm Window Width = 39mm Strip Width = 70mm = 39.5mm Core Build Mass = 9.1kg Mean path = 0.45m

1.4

1.2

1.0

Core Type 1 Phase Window Length = 229mm Window Width = 89mm Strip Width = 210mm = 60mm Core Build = 77.7kg Mass Mean Path = 0.84m

Core Type 1 Phase Window length = 119mm Window Width = 39mm Strip Width = 70mm = 39.5mm Core Build Mass = 9.1kg Mean path = 0.45m

0.8

0.6

0.4

0.2

0.0 1.7

1.6

1.5

1.4

1.3

1.2

1.1 Flux density (Tesla)

0.9

0.8

0.7

0.6

0.5

0.0 1.7

1.6

1.5

1.4

1.3

1.2

1.1 Flux density (Tesla)

0.9

0.8

0.7

0.6

0.5

Part: 119397039.5 Duo1 1 lamination/overlap not annealed, Material=30rgh110 Part: 119397039.5 Duo3 3 lamination/overlap not annealed, Material=30rgh110

Part: 119397039.5 Duo2 2lamination/overlap not annealed, Material=30rgh110 Part: 119397039.5 Duo1 1 lamination/overlap ANNEALED, Material=30rgh110

Part: 119397039.5 Duo1 1 lamination/overlap not annealed, Material=30rgh110 Part: 2298921060 Duo1 1 lamination/overlap not annealed, Material=30rgh110

Part: 119397039.5 Duo1 1 lamination/overlap ANNEALED, Material=30rgh110 Part: 2298921060 Duo1 1 lamination/overlap ANNEALED, Material=30rgh110

Test Rig for testing Single & Three Phase Unicores

The manual magnetic test rig includes a variac connected to a power meter with either a single phase or three phase test leads around the test core. Test results can be entered into the spreadsheet producing a graph showing interpolated core performance vs flux density for both Power Loss (Watts) and Magnetising Force (A/m).

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Basic info

Unicore machine

DUO & DG core

0.2

DUO assembly

Other cores

Savings

Transformers

References

Examples of Unicore transformers

Transformers
Single-leg transformer

Core type transformer

Petersen coil with DG cores

Shell type transformer with DUO cores, Russia

230 kVA dry type transformer, Slovakia

100 kVA transformer, Italy

Shell-type DUO core transformer, Italy

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3-phase choke, Italy

4-core 5-limb 3-ph transformer, Australia

Examples of instrument transformers

Example of frame

10 MVA transformer, South Africa

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Basic info

Unicore machine

DUO & DG core

DUO assembly

Other cores

Savings

Transformers

References

Transformers

10 kVA transformer, Poland

Three phase 100 kVA transformer, Poland

6.3 kVA transformer, Russia

75 kVA oil distribution transformer, Macedonia

Marine transformer, Norway

100 kVA transformer, Czech Republic 40 kVA transformer with NOSS core, Turkey

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2 kVA transformer with Stepbutt core

Some references
Europe ALCE Elektrik, Turkey Elettromeccanica Zucchiatti, Pordenone, Italy Elesa Transformadores, Spain MAKITEL DOOEL, Ohrid, Macedonia Superfin, Berlin, Germany / INTEPS, Pskov, Russia Vakar, Dobr, Czech Republic VP Technotron, Frdek-Mstek, Czech Republic Australia & New Zealand ABB Australia, Darra, Australia AEM Cores Pty, Ltd, Gillman, Australia ETEL Distribution Transformers, Auckland, New Zealand Thycon, Coburg, Australia Tyree Transformers, Mittagong, Australia Asia ETAH SDN. BHD., Kuala Lumpur, Malaysia Jupiter Electricals, Vadodara, India Han Chang Trans Co, Busan, Korea Kotsons, Agra, India Mangal Electrical Industries, Jaipur, India Manu Power Equipments Pvt, Ltd. Hyderabad, India Neptune Stampings, Vadodara, India Patson Transformers, Gujarat, India Star Delta Transformers, Shopal, India Uttam Electricals Ltd., Jaipur, India Africa Alloy Magnetic Cores, Elsburg, South Africa Areva, Johannesburg, South Africa

DUO transformer used for vacuum tube amplifier North America ABB Inc, Jefferson City, Missouri, USA Ambar Electroingenieria, Ecatepec, Mexico BCL Magnetics, Burlington, Ontario, Canada Carte International, Winnipeg, Canada Condumex, Laredo, Mexico CorMag, Burlington, Ontario, Canada Eaton Electrical, Arden, North Carolina, USA El-Met-Parts, Dundas, Ontario, Canada Electromagnetic Ind., Clearwater, Florida, USA Instrument Transformers, Clearwater, Florida, USA Kuhlman Electric Corp., Versailles, Kentucky, USA LakeView Metals Inc., Winthrop Harbor, Illinois, USA Magnetic Metals, Anaheim, California, USA Pauwels Transformers, Missouri, USA Power Magnetics, Gardena, California, USA Prolec GE, Apodaca, Mexico TC Metals, City of Commerce, California, USA South America Caivet Transformadores, Caracas, Venezuela CNS, Sao Paulo, Brazil INATRA, Guyaquil, Ecuador Rhona S.A., Vina Del Mar, Chile Rymel Engenieria Electrica, Itaqui-Autoquia, Colombia Siemens, Bogota, Colombia

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Basic info

Unicore machine

DUO & DG core

DUO assembly

Other cores

20 kVA transformer with DG core, Slovakia

Savings

Transformers

References

Cruciform 630 kVA DUO2 core from 8 strips

Agent for Europe AEM Cores Pty. Ltd. 95 Bedford Street, Gillman SA 5013, Australia Tel.: +61 8 8341 0086 Fax: +61 8 8341 0225 sales@aemcores.com.au www.aemcores.com.au Subagents in Europe Ruff s.r.o. Tyrova 1033, 744 01 Frentt p. R. Czech Republic Tel.: +420 608 834 747 Fax: +420 556 831 701 info@ruff.cz www.ruff.cz
Austria, Germany & Switzerland Schppi Industrievertretungen Geissweidli 5 CH-8846 Willerzell Tel./Fax: ++41 55 422 00 40 Tel.: ++41 79 620 35 47 pschaeppi@bluewin.ch Russia TC Windeq Domodedovskoe shosse, 1/3 Moscow 142116 Tel.: ++79 261 939 494 Tel.: ++79 263 789 898 info@windeq.com France Mrs. Lydia Cayeux 15, chemin des Beaudenons 45220 St Germain des Prs Tl.: ++33 2 38 94 63 32 Fax: ++33 2 38 94 64 01 cayeux.tct@wanadoo.fr Turkey UYGAR Teknoloji Mhendislik Elektrik Makineleri San. ve Tic. Ltd. Sti. 1420 Sokak No: 30/1-1 35220 Kahramanlar-IZMIR Tel.: ++90 232 445 51 62 Fax: ++90 232 445 51 63 uygartekno@superonline.com Spain MPTECNOIMPORT, S.L. Nord, 76 Local 20 08950 Esplugues de Llobregat Tel.: +34 93 473 7975 Fax: +34 93 473 7992 info@mptecnoimport.com

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