A CORE PART OF: EFFICIENT ENERGY DISTRIBUTION INNOVATING TRANSFORMERS YOUR OPERATIONAL SUCCESS

Transcription

1 A CORE PART OF: EFFICIENT ENERGY DISTRIBUTION INNOVATING TRANSFORMERS YOUR OPERATIONAL SUCCESS

2 2 January 2017

3 UNICORE CATALOGUE THE RANGE AND THE FACTS Contents Unicore Machinery UCM440A UCM425 and UCM UDM TCT Unicore Products Single Phase Three Phase DUO Core Distributed Gap Cores Cruciform Stepbutt Butt-2 Core & Butt-3 Core Gapped Core Uncut Core Dee Core Straight Laminations Unicore manufacturing examples Assembly of Unicores Single Phase DUO Core Three Phase DUO Core Single Phase Distributed Gap Cruciform Examples of transformers Agents

4 INTRODUCING OUR CORE VISION Since 1958 AEM has been driven by the vision to improve the efficiency of transformer core technology throughout the entire value chain. This means better manufacturing machines, better core products and better performance in the field. With the cleantech age upon us, our original ideals have proven to be far ahead of the times. AEM is firmly committed to continue as a leader in highly efficient core technologies. Generating efficiency in 3 key areas 4 CORE MANUFACTURING UNICORE PRODUCTS IN THE FIELD Reduce manufacturing foot print and delay investment into larger machines Easy and affordable design, assembly and manufacture Proven performance to improve distribution efficiency

5 A CORE PART OF THE BIGGER ISSUES Climate change is driving economies and technologies to be more efficient, eliminate waste, reduce carbon emissions and provide sustainability. Whether you believe in climate change or not, is not the issue. Carbon emission schemes and taxation will affect believers and non-believers alike, we will all pay, and hence must play a part. AEM has been producing high quality cores and core machines long before the term carbon credits was created. Our core value is to vastly improve efficiencies throughout the significant value chain that has been our focus since Our Unicore products and manufacturing machines are now the preferred choice for many small, medium and multinational transformer manufacturers worldwide. With such significant acceptance, we see the opportunity to enhance our part in the energy industry. Helping you play an even bigger part in the overall energy and cleantech solution. 5

6 A CORE PART OF For General Purpose and Distribution Transformers our core products have enhanced efficiency in many ways Unicores hold a number of advantages over other types of magnetic cores for general purpose and distribution transformers. With lower loss, efficient production and ease of assembly, our Unicores have helped innovate transformers around the world. The gap has widened even further with the DUO core, which not only provides exceptional energy efficiency, it is also very simple to assemble. The future for DUO core will be to replace large E&I, strip laminations and C cores, which struggle to meet the need for greater energy efficiency. Our comprehensive range of Unicores Each type is able to be customised and made to exacting specifications. DUO Distributed gap Cruciform Stepbutt Butt Gapped Uncut Single phase and Three phase versions OUR EXPERTISE HAS DEVELOPED A RANGE OF UNICORES, BASED ON THREE KEY CRITERIA: Must be the most efficient in terms of reducing core loss Must perform with low loss and affordability Must be easy to use, assemble and handle 6

7 INNOVATING TRANSFORMERS PERFORMANCE Typically used for distribution and general purpose transformers from 1 kva to 1.5 MVA or more. MATERIALS Produced from any grade of Grain Oriented Silicon Steel (GOSS). Thickness from 0.15 to 0.35 mm. Strip width from 20 to 425 mm (dependant on machine specification chosen). GEOMETRY & SIZES Weight: Up to 1500kg Unicore faces: Distributed gap, DUO core, straight butt or uncut Corners: 30, 45, 90 - depending upon application Simple to specify and produce to suit your design. Parameters Window Length (WL) Strip Width (SW) Strip Thickness (ST) Window Width (WW) Build-up (BU) Corner Angle 7

8 A CORE PART OF The lasting passion for continual efficiency that began in 1958 In fifty years we have gone from a manufacturer of arc welders to a leading global supplier of Unicore machines and Unicores. The one thing that has been common throughout the journey has been the question, How to improve efficiency at each and every step? The small size of the Australian transformer core market inspired AEM to develop flexible automated machinery for core manufacture. The company was also committed to innovating core design. The result has been the creation of Unicore machines that produce the exceptional Unicores. Unicores are highly regarded in the market as the most advanced and efficient available. And the machines themselves are prime examples of improving efficiency. Over 250 Unicore machines sold globally Unicore machines eliminate the need for fixed tooling such as jigs and mandrils. Unicore laminations are fully formed by the machine. For the operator, flexibility, accuracy and reliability are key advantages. Reduced core/coil assembly time results in reduced transformer costs. MANUFACTURING HIGH QUALITY CORES HAS NEVER BEEN EASIER BEFORE YOU BUY A LARGE EXPENSIVE CORE MACHINE... Fully programmable for flexible production Produces fully formed cores Eliminates manual forming Reduces need for annealing Minimises core loss Automated, with no tooling required Just-in-time production runs Convenience of smaller size, less weight Superior product, with same affordability Easier to handle and store AEM Unicore machines have minimal footprint They are highly affordable Require minimal inventory Multiple machines vastly increase production capacity for far less cost Delay extensive capital investment 8

9 YOUR OPERATIONAL SUCCESS Simple and flexible production The core design screen offers a simple Graphic User Interface for operators to make selections, configure and produce at a rate that suits your requirements. High speed production for Just-in-Time performance A spreadsheet is available to calculate core production times. Reduce annealing costs Unicores are fully formed by the machine. Annealing will reduce core loss on small to medium sized cores but costs can be saved if this is not necessary. Large Unicores have very low loss, so annealing costs can be saved. ROI can be as low as 6 to 9 months 9

10 AEM UNICORE UCM440A AUTOMATIC DUO CORE MACHINE MODEL UCM440A AEM has developed automated machinery for the production and stacking of DUO half cores, removing the need for an operator to build the core halves. New Features Process 1 strip up to 440 mm (17 ) or 2 strips up to 220 mm (8.5 ) each Integrated dust extraction hood Industrial touch screen controller Four cutting edges per carbide blade Servo motor driven cut, fold and feed Reduced labour costs The UCM440A can produce and stack DUO core half cores within the following ranges: WL (mm) WW (mm) SW (mm) (2 strips) (1 strip) BUp (mm) ST (mm) Max 1/2 core mass 200 kg (2 strips) 350 kg (1 strip) 10

11 UNICORE MACHINERY AEM UNICORE UCM300 & UCM425 MODEL UCM300 (300 mm/12 inch) MODEL UCM425 (425 mm/16 inch) For General Purpose & Distribution Transformers (500 VA 5000 kva) New Features UCM300 process 1 x 300 mm or 2 x 140 mm strips UCM425 process 1 x 425 mm or 2 x 210 mm strips Integrated dust extraction hood Industrial touch screen controller Four cutting edges per carbide blade Servo motor driven cut, fold and feed Lower operating costs Quieter operation Faster Hydraulic Expansion Mandrel Non-contact Induction Sensors Typical Installation 11

12 AEM DECOILER UDM4000 Description Suitable for most industries requiring decoilers Push button hydraulic expanding mandrel Maximum coil width 450 mm Maximum coil weight 2000 kg Maximum mandrel diameter 525 mm Minimum mandrel diameter 460 mm Speed range 5-30 rpm by VF drive Strip sensing non-contact induction sensor Power VAC 3 ph Can be powered from the AEM Unicore machine 12

13 UNICORE MACHINERY PRODUCTS CORE AEM TRANSFORMER CORE TESTER TCT150 Core Tester for Toroids & Single Phase Unicores Test cores at 50Hz, 60Hz and up to 400Hz Test various material types C.R.G.O., Ni Fe & Amorphous Minimum core ID = 36 mm Minimum core cross section = 10x10 mm Maximum core OD = 700 mm Maximum core height = 220 mm Flux densities from 0.02 to 1.8 Tesla Maximum Magnetising Force H up to 300AT/m User replaceable test clamp pins Multiple test clamp sizes are available Number and size of test clamps will be determined by the range of core sizes and material to be tested For integration into a production line a test clamp may be rear mounted and a weigh scale added Cores are degaussed Test certificate (adhesive label) printed Test data is archived User configurable test points Note - TCT150 capabilities are relative to core dimensions and material type. Please provide us with the specifications of the cores to be tested for verification of capabilities. Testing capabilities can be customised to your requirements. 13

14 PHASE SINGLE PHASE Description DUO Core is well suited to Core Type Single Phase Transformers. When used for Shell Type, the core leg outside the coils should be held tight. PHASE THREE PHASE Description DUO Cores are very well suited to Evans style (Core Type) Three Phase Transformers. They are also very good for the inner cores of a 4 core / 5 limb transformer. 14

15 UNICORE PRODUCTS CORE 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 Distribution and General Purpose Transformers. Annealed DUO cores with one lamination per overlap will have the lowest core loss. After assembly into windings TIG welding of the last lamination and wedging is recommended. 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 magnetising VA will increase. Material Any grade of GOSS, thickness 0.2 to 0.35 mm. DUO Sizes Dimension Minimum (mm) Maximum (mm) Window Length (WL) 80 Unlimited* Window Width (WW) 40 Unlimited* Strip Width (SW) 20 (with two strips) 300/425 (with one strip) Build Up (BU) Material Thickness Unlimited* * Not limited by the Unicore machine. Limited only by practical transformer manufacturing considerations. Optional Annealing Annealing reduces losses by 5 to 30%, depending on the core size. No Banding Simple TIG weld of final lamination only. GAP DISTRIBUTED GAP CORES Application DG Unicores represent a family of cores with a single cut per lamination. They are used for single-leg and shell type, 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. Material Any grade of GOSS, thickness 0.2 to 0.35 mm. Optional Annealing Annealing reduces losses by up to 30% depending on the core size. For smalller sizes, it is required to achieve the highest efficiency. For larger sizes, the costs of annealing can be saved. DG Unicore Sizes Dimension Minimum (mm) Maximum (mm) Window Length (WL) 60 Unlimited* Window Width (WW) 40 Unlimited* Strip Width (SW) 20 (with two strips) 300/425 (with one strip) Build Up (BU) Material Thickness Unlimited* * Not limited by the Unicore machine. Limited only by practical transformer manufacturing considerations. 15

16 CRUCIFORM Description For use with round or oval coils a Unicore may be made from multiple strip widths. The resultant core legs have a cruciform cross section. STEPBUTT Description This type of Unicore is used only for a shell type General Purpose Transformers to replace laminations, up to approx. 2 kva. Its losses are much higher than DUO or DG Unicores, lower than or comparable to a C core but much lower than laminations. 16

17 UNICORE PRODUCTS CORES BUTT-2 CORE AND BUTT-3 Description These cores have a gap of programmable size in 2 (single phase) or 3 (3-phase) legs. They are used in chokes and reactors. 17

18 GAPPED CORE GAPPED CORE Description It is a Single Phase core with one gap of programmable size in one leg only. UNCUT CORE UNCUT CORE Description 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 magnetising current. 18

19 UNICORE PRODUCTS CORE DEE CORE FOR VOLTAGE TRANSFORMERS Description DG core with unequal corner sizes promotes uniform shrinkage of resin, reducing the likelihood of voids forming. LAMINATIONS STRAIGHT LAMINATIONS Description The Unicore machine can be programmed to produce rectangular 90 cut laminations which can be used for the manufacture of chokes and transformers. 19

20 MANUFACTURING MANUFACTURING INTEPS, Russia Makitel, Macedonia Therma FM, Czech Republic 20

21 MANUFACTURING EXAMPLES MANUFACTURING MANUFACTURING 21

22 SINGLE PHASE 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. I nsert 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. A fter welding the outer lamination an insulation material may be used to lightly wedge the remaining space between the core and the coil. 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 The disassembled core Male half of the core 22 Female half of the core Taking a male packet Partly assembled core without bobbins Taking a female packet DUO3 detail Assembly plates

23 ASSEMBLY OF UNICORES PHASE THREE PHASE DUO CORE ASSEMBLY Procedure Assembly of a three phase DUO core is very similar to the single phase 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 and wedge firmly in the outer coils. Then weld. Example of a Cast Resin Transformer Core weight: 164 kg Transformer power: 50 kva Core production time: 41 min Core assembly time: approx. 50 min An assembly table First inner core assembled Inserting first lamination Strapping the core Wedging the inner cores Start of outer core assembly Inserting female packet 23

24 SINGLE PHASE SINGLE PHASE DISTRIBUTED GAP CORE 25 kva Core Type Dry Transformer With DG Core Core size: WL 300, WW 160, SW 130, BUP 67 Core weight: 73 kg Core production time: 21 min Core assembly time: approx. 45 min 24

25 ASSEMBLY UNICORE OFPRODUCTS UNICORES CRUCIFORM CRUCIFORM CORE ASSEMBLY 25 kva Dry Distribution Transformer With DDG Core Core size: W L 280, WW 128, SW 60/90/120, BU 116mm 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 min 25

26 VOLTAGE TRANSFORMERS Unicore Advantages A voltage transformer (VT) must produce signals (voltages) which very precisely reflect the (usually high) input voltages. Thus the voltage ratio(s) must be precisely known (and substantially invariant with voltage at least over a range) and the phase errors (output vs corresponding input) must be small, known and again reasonably constant. Further, the output voltage must change little with load (burden, as with current transformers). Errors in VT s are attributable to the usual (low frequency) transformer imperfections, namely finite primary and secondary winding resistances and leakage reactances and the finite magnetising current and core loss. Unicore technology offers considerable advantages over C-cores and stacked laminations. The very small effective air gap, achieved by the distributed gap of the Unicore, reduces very significantly (almost an order of magnitude) the quadrature component of magnetising current, which in turn is largely responsible for the phase errors in a voltage transformer. Therefore, excluding any variations to external factors, the use of a Unicore should result in a substantial reduction in phase errors. 26

27 EXAMPLES UNICORE OF TRANSFORMERS PRODUCTS TRANSFORMERS DISTRIBUTION TRANSFORMERS 100 kva transformer, Italy 10 MVA transformer, South Africa 4-core 5-limb 3-ph transformer, Australia Three phase 100 kva transformer, Poland 27

28 DISTRIBUTION TRANSFORMERS 28

29 EXAMPLES OF TRANSFORMERS UNICORE PRODUCTS TRANSFORMERS GENERAL PURPOSE TRANSFORMERS Core type transformer Shell type transformer with DUO cores, Russia Single-leg transformer 29

30 AGENTS AGENTS Head Office All enquiries will be directed to your local AEM Agent. AUSTRALIA AEM Cores Pty Ltd 95B Bedford Street Gillman, South Australia 5013 T: F: E: sales@aemcores.com.au W: World-wide Agents North America & Mexico India, Bangladesh, Sri Lanka Europe Taiwan & China Africa Russia Japan South America South Korea The Middle East Pakistan 30

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32 95B Bedford Street Gillman South Australia 5013 T F sales@aemcores.com.au