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  • Unveiling the Magnetic Marvel: The Fascinating World of Orientation Silicon Steel Unveiling the Magnetic Marvel: The Fascinating World of Orientation Silicon Steel
    Nov 05, 2024
    In the realm of materials science, there exists a star that shines brightly in the field of electrical engineering – orientation silicon steel, or simply, oriented silicon steel. This isn't just any ordinary metal; it's a technological wonder that revolutionizes the way we think about electricity and magnetism. Imagine a material so refined and engineered that it exhibits exceptional magnetic properties, making it the go-to choice for transformers and other electrical devices. Oriented electrical steel undergoes a complex manufacturing process involving rolling and annealing to align its magnetic domains in a specific direction. This alignment is crucial, as it significantly reduces energy loss during the transformation of electrical energy, enhancing efficiency by leaps and bounds. But why should we care? Well, in today's world where sustainability and energy efficiency are paramount, every little bit of energy saved counts. Transformers equipped with orientation silicon steel play a pivotal role in reducing electricity wastage, thereby contributing to greener, more eco-friendly power grids. Moreover, the material's thin gauge and high permeability allow for more compact transformer designs, making it an invaluable asset in the ever-shrinking world of electronics. From large-scale power stations to the tiny transformers inside our gadgets, orientation silicon steel is there, silently working its magic. So, the next time you marvel at the seamless flow of electricity that powers your life, remember the unsung hero behind the scenes – orientation silicon steel. It's a material that's not just about steel; it's about innovation, efficiency, and a brighter, more sustainable future.
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  • Why is lamination used in the core of a transformer? Why is lamination used in the core of a transformer?
    Oct 17, 2024
    Transformers are electrical devices that transfer electrical energy between two or more circuits through electromagnetic induction. Transformers consist of two main components: a primary winding and a secondary winding, both wound around a core. The transformer core of a transformer plays a crucial role in its efficient operation. It is typically made using laminations or stacked layers of a magnetic material, such as silicon steel. But why is lamination used in the core of a transformer? Let's delve deeper into this question. The primary reason for using laminations in the transformer core is to minimize energy losses. When an alternating current (AC) flows through a transformer, the magnetic field generated by the current causes the core to undergo rapid magnetization and demagnetization cycles. These cycles lead to two types of energy losses in the transformer core: hysteresis loss and eddy current loss. Hysteresis loss occurs due to the repeated flipping of magnetic domains within the core material, resulting in energy dissipation in the form of heat. Laminating the core helps to reduce this loss by segmenting the core into thin layers. These layers disrupt the continuous path for magnetic flux, reducing the area enclosed by the hysteresis loop and thus minimizing hysteresis loss. Eddy current loss, on the other hand, is caused by the circulating currents induced within the core material due to the varying magnetic field. By using laminations, the transformer core is effectively divided into isolated pieces, reducing the continuous loops that the eddy currents can flow through. This segmentation significantly decreases the cross-sectional area available for eddy currents and, consequently, reduces eddy current losses. Moreover, laminations also enhance the mechanical strength and stability of the transformer core. By stacking and tightly clamping the laminations together, the core becomes more rigid and less susceptible to mechanical stresses and vibrations. This ensures that the core maintains its integrity and optimal magnetic properties throughout the transformer's operation. In summary, the use of laminations in the core of a transformer is essential for minimizing energy losses, particularly hysteresis and eddy current losses. By dividing the core into thin layers, laminations reduce the path for magnetic flux and circulating currents, resulting in improved efficiency and overall performance of the transformer. Additionally, laminations enhance the mechanical stability of the core. These factors collectively contribute to the reliable and efficient operation of transformers in applications.
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  • The Significance of Lamination in Transformer Cores The Significance of Lamination in Transformer Cores
    Oct 12, 2024
    Transformers are essential electrical devices that facilitate the efficient transmission and distribution of electrical energy. At the heart of every transformer lies its core, which plays a crucial role in transforming voltage levels. One commonly employed technique in constructing transformer cores is lamination. In this article, we will explore why lamination is used and delve into its significance in the design and performance of transformer cores.  Why COGO Lamination? The primary reason for incorporating CRGO laminations in transformer cores is to mitigate energy losses caused by magnetic characteristics while maintaining optimal performance. Laminated cores consist of numerous thin layers of a magnetic material, typically silicon steel, stacked together and insulated from each other. This technique introduces several benefits that enhance the efficiency and reliability of transformers.   Reducing Eddy Current Losses: When an alternating current flows through the primary winding of a transformer, it induces a magnetic field in the core. However, this varying magnetic field can induce small circulating currents, known as eddy currents, within the solid core material. These eddy currents generate heat and consume a significant amount of energy, leading to undesirable energy losses. Lamination effectively addresses this issue by breaking up the solid core into thin insulated layers, thus interrupting the flow of eddy currents and minimizing energy dissipation as a result.     Controlling Magnetic Flux: Lamination also helps in controlling the flow of magnetic flux within the transformer core. By dividing the core into multiple layers, each with its own magnetic path, laminations ensure that the magnetic flux follows a desired and efficient route. This controlled flux path minimizes magnetic leakage and maximizes the coupling between the primary and secondary windings, leading to improved transformer performance.   Reducing Hysteresis Losses: Hysteresis loss occurs when the magnetic field within the core material repeatedly reverses its polarity with each alternating cycle. By using laminations, the size of the hysteresis loop, and thus the associated hysteresis losses, can be significantly reduced. This is achieved by carefully selecting the thickness and composition of the laminations, optimizing the magnetic properties and reducing energy losses within the core. SO… Lamination is a fundamental technique employed in transformer core design to enhance efficiency and reduce energy losses. By effectively controlling eddy currents, magnetic flux, and hysteresis losses, laminated transformer cores ensure optimal performance and improve the overall energy efficiency of electrical power distribution systems. As technologies continue to advance, the use of advanced laminated materials and designs will further contribute to the evolution of efficient and sustainable transformers.
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  • Transformer Cores: Enhancing Efficiency and Performance with Silicon Steel Transformer Cores: Enhancing Efficiency and Performance with Silicon Steel
    Jun 06, 2024
    Transformer cores play a crucial role in the efficient operation of transformers. These cores are typically made of a material called silicon steel, which possesses excellent magnetic properties. In this article, we will explore the significance of transformer cores, highlight different types of cores, and discuss their application scenarios. 1. Importance of Transformer Cores: Transformer cores serve as the magnetic circuit that facilitates energy transfer between the primary and secondary windings of a transformer. Their primary function is to provide a low-reluctance path for the magnetic flux generated by the alternating current, resulting in efficient energy conversion. By utilizing high-quality silicon steel, transformer cores minimize energy losses and enhance overall performance. 2. Silicon Steel and its Benefits: Silicon steel, also known as electrical steel or laminated steel, is the preferred material for transformer cores due to its magnetic properties. It contains silicon in specific compositions to reduce magnetic losses caused by eddy currents and hysteresis. Silicon steel offers low core losses, high permeability, and excellent saturation induction, making it an ideal choice for transformer cores. 3. Types of Transformer Cores: E-Core: The E-shaped core is one of the most commonly used transformer cores. It offers high winding space utilization and allows the primary and secondary windings to share a common structure. The E-core design provides efficient flux distribution and minimizes stray magnetic fields, resulting in improved performance and reduced losses. C-Core: The C-core is another popular design for transformer cores. It is fabricated by winding silicon steel strips into a closed core shape. C-cores offer a compact and lightweight structure, ensuring high energy efficiency. With carefully designed air gaps and optimal winding configurations, C-cores exhibit low losses and excellent magnetic performance. 4. Application Scenarios: Power Distribution Transformers: Both E-core and C-core transformer designs find extensive applications in power distribution systems. E-cores are commonly employed in high-power transformers where efficiency and compact size are essential considerations. C-cores, on the other hand, are suitable for smaller transformers used in residential or commercial applications. Audio Transformers: E-cores are often utilized in audio transformers where quality and fidelity are critical. These transformers ensure effective signal transmission and minimize distortion. The superior magnetic properties of silicon steel cores contribute to improved audio performance, offering clean and accurate sound reproduction. Renewable Energy Systems: Transformers used in renewable energy systems, such as solar and wind power, require efficient energy conversion. Both E-cores and C-cores can be employed depending on the specific requirements of the system. These cores enable effective power transmission, reducing energy losses and maximizing the utilization of renewable resources. Transformer cores, made of silicon steel, are vital components that optimize the efficiency and performance of transformers. Whether in power distribution, audio applications, or renewable energy systems, the choice of E-cores or C-cores depends on the specific design considerations. By leveraging the high magnetic permeability and low core losses of silicon steel cores, transformers can deliver optimal functionality in various operational scenarios.
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  • Transformative Core Materials: CRGO & CRNGO for Optimal Performance in Transformers Transformative Core Materials: CRGO & CRNGO for Optimal Performance in Transformers
    May 27, 2024
    Transformers play a vital role in electrical power systems, enabling efficient transmission and distribution of electricity. At the heart of every transformer lies the core, a crucial component that ensures the smooth conversion of electrical energy between different voltage levels. This article will explore two commonly used core materials in transformers, CRGO (Cold-Rolled Grain Oriented) and CRNGO (Cold-Rolled Non-Grain Oriented), highlighting their characteristics, advantages, and application scenarios. CRGO Transformer Cores CRGO cores are widely employed in power transformers, where high efficiency and low core losses are crucial. The production process involves cold-rolling a silicon steel strip to align the grains in the crystal lattice structure, resulting in excellent magnetic properties. CRGO cores exhibit the following key features: Reduced Core Losses: The grain-oriented structure of CRGO cores minimizes magnetic hysteresis and eddy current losses, leading to superior energy efficiency and reduced heat generation. High Magnetic Permeability: CRGO cores exhibit high magnetic permeability, enabling efficient magnetization and demagnetization cycles during power conversion processes, thus enhancing overall transformer performance. Low Magnetostriction: Magnetostriction is the phenomenon where a material changes shape under the influence of a magnetic field. CRGO cores have low magnetostriction, reducing mechanical stress on the transformer and minimizing audible noise. Application Scenarios: CRGO cores are commonly used in large power transformers, distribution transformers, and high-power applications due to their excellent energy conversion efficiency and performance stability over a wide range of operating conditions. CRNGO Transformer Cores CRNGO cores are predominantly employed in low and medium-power transformers, along with various electrical machines, such as motors and generators. Unlike CRGO cores, CRNGO cores do not possess grain-oriented crystal structures. Their key characteristics include: Enhanced Permeability: Although lower than CRGO cores, CRNGO cores still exhibit reasonable magnetic permeability, making them suitable for applications requiring moderate power conversion efficiency. Lower Production Costs: The absence of grain orientation in CRNGO cores simplifies the manufacturing process, resulting in reduced production costs compared to CRGO cores. Wide Variety of Shapes: CRNGO cores can be easily tailored into different shapes and sizes, allowing for design flexibility and customization to meet specific application requirements. Application Scenarios: CRNGO cores find extensive use in lower-power transformers, small power supplies, electric vehicles, and other applications demanding cost-effectiveness and optimal performance within a limited operating range. Selecting the appropriate transformer core material is critical to achieving optimal performance and efficiency in various electrical applications. CRGO cores excel in high-power transformers, where minimal losses and excellent energy conversion are paramount. On the other hand, CRNGO cores find applications in low-to-medium-power transformers, motors, and generators, offering a balance between performance and cost-effectiveness. Understanding the characteristics of these transformative core materials is essential for designing reliable and efficient electrical systems. As a leading transformer manufacturer, our company specializes in producing high-quality transformer cores tailored to meet the diverse needs of our customers. Whether you require CRGO or CRNGO cores, we are committed to delivering exceptional products that optimize performance and contribute to the advancement of electrical power systems. We welcome you to contact us for any transformer core requirements or further inquiries.  
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  • TEN differences between dry-type transformers and oil-immersed transformers TEN differences between dry-type transformers and oil-immersed transformers
    Mar 27, 2024
    Recently, we received some inquiries from customers about dry-type transformers and oil-immersed transformers. As you may know, dry-type transformers are generally more expensive compared to oil-immersed transformers. But why? What’s the difference between them? Let Catherine explain it to you today! Installation Location Dry-type transformers are preferred for indoor locations such as basements, floors, and rooftops, especially in areas with high human population density oil-immersed transformers are typically used in substations. Application Box-type transformers are generally used for indoor applications, while oil-immersed transformers are commonly used for outdoor temporary power supply. Space Considerations The choice between dry-type and oil-immersed transformers depends on the available space. oil-immersed transformers are suitable for larger spaces, while dry-type transformers are preferred in compact spaces. Climate: oil-immersed transformers are more suitable for humid and hot environments. If dry-type transformers are used in such conditions, they must be equipped with forced air-cooling systems. Appearance Dry-type transformers have visible cores and coils, while oil-immersed transformers are enclosed and only the outer shell is visible. Connection Dry-type transformers mostly use silicone rubber bushings, while oil-immersed transformers often use porcelain bushings. Capacity and Voltage Dry-type transformers are mainly used for distribution purposes, with capacities up to 1600 KVA and voltages below 10 KV. oil-immersed transformers can handle all capacities and voltage levels, including high voltage such as 1000 KV. Insulation and Cooling Dry-type transformers use resin insulation and rely on natural or forced-air cooling, while oil-immersed transformers use insulating oil for insulation and heat dissipation through radiators or cooling fins. Suitable Locations Dry-type transformers are commonly used in fireproof and explosion-proof environments, often in large and high-rise buildings. On the other hand, oil-immersed transformers are typically installed outdoors with provisions for an "incident oil pit" in case of leaks or spills. Load-Bearing Capacity Dry-type transformers should operate within their rated capacity, while oil-immersed transformers have better overload capacity. Cost Dry-type transformers are generally more costly compared to oil-immersed transformers of the same capacity. If you want to know more about transformer cores, especially hope to purchase some good transformer cores in China. Contact SHUNGE! We will be very glad to help!  
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  • What is the difference between adding or not adding an iron core to the transformer? What is the difference between adding or not adding an iron core to the transformer?
    Mar 14, 2024
    Transformer is a device that converts AC voltage, current and impedance. When AC current flows through the primary coil, AC magnetic flux is generated in the iron core (or magnetic core), causing voltage (or current) to be induced in the secondary coil. A transformer consists of an iron core (or magnetic core) and a coil. The transformer core is the main magnetic circuit of the coupled magnetic flux in the transformer. Working principle of transformer core The function of the core of the transformer is to form a magnetic circuit of coupling flux with very small reluctance. Because the reluctance is very small, the working efficiency of the transformer is greatly improved. Broadly speaking, transformers are divided according to the coupling material between coils, including air core transformers, magnetic core transformers, and iron core transformers. Air core transformers and magnetic core transformers are mostly used in high frequency electronic circuits. Because silicon steel itself is a material with strong magnetic permeability, it can produce greater magnetic induction intensity in the energized coil, which can reduce the size of the transformer and improve the working efficiency of the transformer. The characteristic of silicon steel is that it has the highest saturation magnetic induction intensity (above 2.0T) among commonly used soft magnetic materials. Therefore, when used as a transformer core, it can work at a very high operating point (such as an operating magnetic induction value of 1.5T). However, silicon steel also has the largest iron loss among commonly used soft magnetic materials. In order to prevent the iron core from heating due to excessive losses, its frequency of use is not high and it generally can only work below 20KHz. Therefore, the frequency of power circuits is mostly Around 50Hz. Our New-build transformer core Shunge Company not only provides first-hand silicon steel sheet raw materials, but also can customize finished transformer cores for customers. If you have any needs, please contact us.
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  • How does a transformer achieve voltage transformation? How does a transformer achieve voltage transformation?
    Jan 15, 2024
    Transformers achieve voltage transformation through electromagnetic induction. When an alternating current (AC) flows through the primary winding of the transformer, it generates a changing magnetic field. This changing magnetic field induces a voltage in the secondary winding based on the turns ratio between the primary and secondary windings. As a result, the voltage is stepped up or stepped down without altering the frequency, allowing efficient transmission of electrical energy across different voltage levels. A transformer operates based on the principle of electromagnetic induction. It consists of two insulated windings wound around a closed iron core. These windings, known as the primary winding or the first winding, and the secondary winding or the second winding, have different numbers of turns and are only magnetically coupled without electrical connection. When the primary winding is connected to an AC power source, an alternating current flows through it, creating an alternating magnetic flux in the iron core. This flux induces voltages, denoted as e1 and e2, respectively, in the primary and secondary windings at the same frequency. When a load is connected to the secondary winding, the voltage e2 causes the current to flow through the load, enabling the transfer of electrical energy. This accomplishes the voltage transformation. According to Equation, the magnitude of the induced voltage in the primary and secondary windings is proportional to their respective numbers of turns. Since the induced voltage is approximately equal to the actual voltage of the windings, by having different numbers of turns in the primary and secondary windings, the voltage conversion in a transformer can be achieved.
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  • What is a core in the transformer? What is a core in the transformer?
    Jan 22, 2024
      The core of the transformer is the magnetic circuit part of the transformer.  It is usually made of hot-rolled or cold-rolled silicon steel sheets with a high silicon content and coated with insulating paint on the surface. The iron core and the coils wound around it form a complete electromagnetic induction system. The amount of power transmitted by the power transformer depends on the material and cross-sectional area of the core.   The iron core is one of the most basic components of the transformer. It is the magnetic circuit part of the transformer. The primary and secondary windings of the transformer are on the iron core. In order to improve the permeability of the magnetic circuit and reduce the eddy current loss in the iron core, the iron core is usually Made of 0.35mm, surface insulated silicon steel sheet. The iron core is divided into two parts: an iron core post and an iron yoke. The iron core post is covered with windings, and the iron yoke connects the iron core to form a closed magnetic circuit. In order to prevent the metal components such as the transformer core, clamps, and pressure rings from inductive floating potential being too high and causing discharge during operation, these components need to be grounded at a single point. In order to facilitate testing and fault finding, large transformers generally have the core and clamps lead out to the ground through two bushings respectively.
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  • What should be done before export silicon steel abroad? What should be done before export silicon steel abroad?
    Sep 19, 2023
    Recently, we have been exporting ten containers of electrical steel to the transformer and motor manufactures in Vietnam. Container Loading Process Inspection is the final stage gate before export. Today I’ll show you what we do before exporting silicon steel. Silicon steel is also known as electrical steel, lamination steel, or transformer steel, and it’s widely used in large motors, relays, solenoids, appliances’ motors, wind turbines, cores of transformers, EV, etc.   There are several required steps before exporting. 1. Labeling. All the labels are customized according to customer demand. No Chinese labels are allowed to show when it comes to exporting. 2. Container Inspection before loading. Inspection of the inside of the container is essential, small holes that light could go through need to take extra caution. Patches, breakages and holes may cause potential damage of the container after delivery.  3. Consolidation. Strong Wooden pallet and wire rope are used to hold and consolidate the coil. We choose 10x10cm durable square wood as the pallet to hold the coil as well as to further fasten and consolidate the 4 corners of the container. Professional loading team is hired to guarantee the loading is strictly in accordance to the requirement of the shipping company.     After all these are done, the containers will head to the port. Waiting to ship! But that is not the end of the order, we will track closely of the vessel and update latest information with our clients until the container deliver safely. 
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  • Three ways of transformer cores manufacturing Three ways of transformer cores manufacturing
    Apr 24, 2023
    There're three methods of manufacturing silicon steel transformer cores: stamping, wire cutting and laser cutting. Stamping Stamping is generally used for producing large quantities of identical metal components through a stamping press. Steel sheet is placed on a stamping press and then it’s positioned and stamped through a die set. Stamping is a more versatile manufacturing process because it can be used for both short and long run production. Stamping sheet is one of the most frequently adapted products. Advantages: - Cost-effective - High accuracy and precision - Produces high-quality output - Suitable for large volume production Disadvantages: - Not suitable for creating intricate designs - Expensive die design Stamping is a widely popular manufacturing process used in areas such as: Automotive, Construction, Aerospace and Electronics.   Stamping machine   Stamping sheet and stamping lamination samples   Wire Cutting Wire Cutting is a manufacturing process that uses a thin wire to precisely cut a work piece into a specific shape. The process involves using a thin metal wire, that is electrically charged, to cut through a work piece of the material.   Advantages: - High accuracy and precision - Can cut through thick materials - Suitable for creating intricate designs Disadvantages of Wire Cutting: - Expensive equipment - Limited to certain types of materials Wire Cutting is used in making a varied range of products including medical devices, aerospace parts, and precision machine components.     Wire cutting machine   Laser Cutting Laser Cutting is a modern manufacturing process that uses a laser beam to cut through materials.  The laser beam is generated by a laser tube inside a laser cutting machine.   Advantages: - Accurate and precise cutting - More energy efficient - Clean cutting edges - Less material waste Disadvantages: - Expensive equipment - Limited to certain types of materials Laser cutting is used in various industries including Aerospace, Architecture, Shop signage, and Metal fabrication.     Laser cutting machine   Laser cutting transformer cores samples   Both ways are available for silicon steel transformer cores manufacturing, there're still several differences between wire cutting and laser cutting: 1. The processes are different. Laser cutting uses a focused high-power density laser beam to irradiate the workpiece, so that the irradiated material is rapidly melted, vaporized, ablated or reaches the ignition point, and at the same time, the molten material is blown away by the high-speed airflow coaxial with the beam, so as to achieve the workpiece cut open. While wire cutting relies on the pulse electric spark discharge between the electrode wire and the workpiece, which generates high temperature to melt or vaporize the metal. 2. Different features for their products. After the material is laser cut, the width of the heat-affected zone is very small, and the properties of the material near the slit are almost unaffected, and the deformation of the workpiece is small, the cutting precision is high, the geometry of the slit is good, and the cross-sectional shape of the slit is relatively smooth. Wire cutting directly uses 0.03-0.35mm metal wire as the electrode, which does not require a specific shape, which can save the design and manufacturing costs of the electrode; regardless of the hardness of the workpiece material, as long as it is a conductor or semiconductor material, it can be processed, and the loss of the electrode wire is small, and the processing High precision; suitable for processing small batches, parts with complex shapes, single pieces and trial products, and the processing cycle is short. 3. They are for different applications. As a precision processing method, laser cutting can cut almost all materials, including two-dimensional cutting or three-dimensional cutting of thin metal plates. Wire cutting is widely used for processing molds; processing parts with fine structures; processing parts with complex shapes; processing hard conductive materials; trial production of new products; blanking of precious metals.     In summary, each manufacturing process has its unique advantages and disadvantages, and it mainly depends on the specific application requirements to determine which process is the best suit. For CRNGO or CRGO silicon steel semi-products, professional customization and sourcing services are provided by Shunge Steel.
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