The primary advantage of amorphous alloy core distribution transformers lies in their exceptionally low no-load losses, making them highly efficient and energy-saving. Ensuring minimal no-load loss is a central concern throughout the entire design process. When arranging the product structure, it's essential to account for the fact that the amorphous alloy core itself is not easily affected by external forces. Additionally, the characteristic parameters of the amorphous alloy must be carefully and accurately selected during calculations.
Beyond this basic principle, three key requirements must also be met:
1. Due to the relatively low saturation magnetic density of amorphous alloys, the rated magnetic flux density should not be set too high during design. Typically, a value between 1.3 and 1.35 T is used to achieve optimal no-load loss performance.
2. The material thickness of amorphous alloy is only 0.03 mm, which limits the lamination factor to around 82% to 86%, affecting the overall efficiency and structural integrity.
3. To ensure long-term reliability and reduce maintenance needs, modern amorphous alloy distribution transformers are typically designed with a fully sealed structure, offering users benefits like maintenance-free operation.
Amorphous alloy cores are known for their excellent magnetic permeability, which allows for very low losses. However, their unique properties require special attention during both design and manufacturing. Key considerations include:
1. Amorphous alloy sheets are very hard and difficult to cut using standard tools, so the design should aim to minimize the amount of shearing required.
2. The thinness of the material (only 0.03 mm) results in a low core filling factor and an uneven surface, which can affect performance if not properly managed.
3. Amorphous alloys are extremely sensitive to mechanical stress. Therefore, traditional designs that rely on the core as a load-bearing component must be avoided.
4. To achieve the best low-loss performance, the amorphous alloy laminations must undergo annealing to improve their magnetic properties.
5. From an electrical performance standpoint, the core is often constructed from four separate frames arranged in a single plane. Each phase winding is placed on two of these frames. This configuration introduces third harmonic fluxes, which cancel each other out when the primary side is connected in a delta configuration. As a result, the secondary voltage waveform remains clean, without third harmonic components.
Based on these considerations, the most effective structure for a three-phase amorphous alloy distribution transformer is a five-column core made up of four individual frames arranged in a plane, with an annealed cross yoke to ensure optimal magnetic performance and structural stability.
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