As the core component of transformers, the iron core plays a decisive role in transformer performance. To meet growing market demand, QXG has actively pursued an expansion plan for its iron core production capacity. Based on extensive market research and technical evaluations, the company has decided to increase production equipment and implement upgrades. The slitting line, being the core equipment for iron core processing, directly impacts the electromagnetic performance of the core and the energy efficiency of transformers through its machining precision. This article analyzes the influence of technical improvements in slitting line processing capabilities and edge burr control on core performance and overall transformer performance.
The processing capability of the slitting line is first reflected in the precise control of the width dimensions of silicon steel sheets. QXG’s new slitting line is equipped with an advanced high-precision CNC system, capable of maintaining extremely tight width tolerances, ensuring dimensional consistency. This improvement reduces air gaps during core stacking, lowers magnetic resistance in the magnetic circuit, and consequently reduces no-load losses.
The high-speed processing capability of the new slitting line not only increases production capacity but also positively impacts core quality stability. During high-speed shearing, the stability of equipment operation and precise control of shear force are critical. QXG’s new slitting line adopts an advanced constant tension control system and dynamic balancing technology, ensuring uniform and stable shear force on silicon steel sheets even at high speeds.
Edge burrs generated during the slitting process are a critical factor affecting core performance. Excessive burrs significantly increase eddy current losses in the core. The presence of burrs roughens the surface of silicon steel sheets, increasing resistance to eddy current flow. For large transformers, this increase in eddy current losses leads to substantial energy waste, reducing the transformer’s energy efficiency.
Edge burrs also negatively affect the insulation performance and magnetization characteristics of the core. During core stacking, burrs may puncture the insulating coating on silicon steel sheets, reducing insulation between adjacent sheets. When insulation is compromised, inter-laminar short circuits can occur during transformer operation, leading to abnormal current flow between sheets, further increasing core heating and energy losses. Additionally, burrs disrupt the uniformity of the magnetic field distribution on the silicon steel surface. In an alternating magnetic field, non-uniform magnetization can lead to inconsistent magnetic states within the core, affecting overall magnetization efficiency.
As the primary carrier of the transformer’s magnetic circuit, the core’s performance directly determines energy conversion efficiency. A high-quality core effectively guides magnetic flux, reduces flux leakage, and minimizes hysteresis and eddy current losses, thereby improving transformer efficiency.
Core performance also plays a crucial role in the operational stability and reliability of transformers. Stable magnetic properties ensure consistent voltage and current output under varying load conditions. If core performance is unstable due to external factors, it may lead to output voltage fluctuations, current distortion, and other issues, affecting the normal operation of the power system.
The increase in QXG core production lines, especially the improvement in processing capacity and edge burr control of the longitudinal shearing line, has had multiple positive impacts on core performance. The optimization of core performance has further enhanced the energy conversion efficiency, operational stability and reliability of the transformer. In the future development, QXG will rely on its technological advantages in core manufacturing to continuously improve product quality, provide more high-quality and efficient transformer core products for the development of the power industry, and promote the continuous progress of power equipment manufacturing technology.