Analysis of the Construction of Amorphous Alloy Transformers

　　An amorphous alloy transformer is a highly efficient and energy-saving transformer that utilizes an amorphous metal core. Its construction is designed to reduce magnetic losses, enhance energy efficiency, and improve environmental adaptability. Below is an analysis from four dimensions: core components, material characteristics, construction details, and technological advantages.

　　1. Core Components and Material Characteristics

　　Amorphous Alloy Core

　　Material Characteristics: The core employs amorphous metal strip (e.g., iron-based or cobalt-based amorphous alloys). The atomic structure is disordered, resulting in extremely low hysteresis and eddy current losses, along with high magnetic permeability.

　　Manufacturing Process: Molten metal is rapidly solidified into an amorphous thin strip (approximately 0.03mm thick) using ultra-fast cooling technology (on the order of millions of degrees Celsius per second), followed by annealing to eliminate internal stresses.

　　Lamination Structure: The core is assembled using either a wound or laminated structure to form a closed magnetic circuit, minimizing leakage flux. For example, three-phase transformers typically adopt a three-phase four-frame five-limb structure, composed of rectangular frame-type monolithic cores.

　　Winding Design

　　High-Voltage Windings: These often utilize a layered and segmented structure, wound with insulated copper or aluminum wires. Insulating paper or film is used between layers, and the segmented design enhances short-circuit resistance.

　　Low-Voltage Windings: A foil structure (copper or aluminum foil) is commonly employed to address axial spiral angle issues, improve ampere-turn balance, and reduce additional losses.

　　Insulation System: High-temperature-resistant insulating materials (e.g., Nomex paper) are used, combined with a vacuum pressure impregnation (VPI) process to enhance insulation performance and moisture resistance.

　　Cooling System

　　Air Natural (AN): Relies on natural convection for heat dissipation, suitable for scenarios with lower load ratios.

　　Air Forced (AF): Equipped with axial fans or radiators to force air circulation, improving cooling efficiency and enabling overload capability up to 140% of the rated capacity.

　　Oil-Immersed (Optional): Some amorphous alloy transformers use oil cooling, though dry-type designs (e.g., SCB18 series) are more environmentally friendly and suitable for indoor installations.

　　2. Construction Details and Design Principles

　　Core Lamination and Assembly

　　Winding Process: Amorphous strips are wound into rectangular frame-type cores using specialized winding machines, reducing joint losses.

　　Lamination Process: Amorphous strips are cut into "E"-shaped or "I"-shaped laminations, which are interleaved, stacked, and secured to form a low-loss magnetic circuit.

　　Magnetic Circuit Optimization: U-shaped spacers and oil gap designs are used to prevent performance degradation due to core stress, reducing noise (typically ≤55dB).

　　Insulation and Protection

　　Layer Insulation: High-voltage windings use DMD insulating paper or polyester film between layers, with a temperature resistance rating of Class F or H.

　　Main Insulation: Insulating cylinders or spacers separate high- and low-voltage windings, with insulating end collars securing the ends to meet power frequency withstand voltage and impulse withstand voltage requirements.

　　Enclosure Protection: Dry-type transformers typically have an enclosure protection rating of IP20/IP23, providing dust and moisture resistance for outdoor or indoor environments.

　　Accessories and Components

　　Temperature Control System: Equipped with an intelligent temperature controller (e.g., Pt100 sensor) for real-time monitoring of winding temperatures, featuring fault alarms, over-temperature tripping, and remote monitoring via RS485 interface.

　　Protective Devices: Built-in gas relays and pressure relief valves automatically cut off power in case of faults, ensuring safety.

　　Voltage Regulation Devices: Some transformers are equipped with off-load tap changers to adjust voltage ratios for grid fluctuations.

　　3. Technological Advantages and Their Relationship with Construction

　　Ultra-Low No-Load Losses

　　The hysteresis and eddy current losses of amorphous alloy cores are only 1/5 to 1/3 of those of silicon steel sheets, significantly reducing no-load losses. For example, the no-load loss of a 35kV amorphous alloy transformer is only 30% of that of a silicon steel transformer.

　　Energy-Efficient Design

　　Optimized core and winding structures reduce leakage flux and additional losses. For instance, the segmented design of high-voltage windings lowers layer-to-layer voltages, reducing transverse leakage flux; the foil-type low-voltage windings improve current distribution, reducing copper losses.

　　Environmental Adaptability

　　Sealed Structures: (e.g., fully sealed transformers) prevent oil leakage and external contaminant ingress, extending equipment lifespan.

　　High Protection Ratings: (IP20/IP23) adapt to humid and dusty environments, such as coastal or mining areas.

　　4. Application Scenarios and Their Relationship with Construction

　　Urban Power Grids

　　Compact Design: (e.g., SCB18-800KVA) is suitable for installation in load centers (e.g., residential areas, commercial complexes), reducing line losses.

　　Low Noise Characteristics: (≤64dB) meet urban environmental requirements.

　　Industrial Applications

　　Explosion-Proof Design: (e.g., fully sealed structures) are suitable for high-dust, flammable, or explosive environments (e.g., mining, metallurgy).

　　High Overload Capacity: (140% rated capacity in forced air cooling mode) accommodates short-term high-load demands.

　　Renewable Energy Integration

　　Energy-Efficient Characteristics: Reduce transmission losses, enhancing the economics of wind and photovoltaic power plants.

　　Wide Temperature Rise Range: (average winding temperature rise ≤100K) adapts to extreme climates (e.g., high-altitude, high-temperature regions).

　　Conclusion

　　The construction of amorphous alloy transformers centers around the amorphous alloy core, optimizing winding design, cooling systems, and insulation protection to achieve ultra-low losses, high energy efficiency, and strong environmental adaptability. Their technological advantages are directly linked to construction details, such as the winding process of amorphous strips, improved current distribution in foil-type windings, and the integration of intelligent temperature control systems. With advancements in materials science and intelligent manufacturing, amorphous alloy transformers will further expand into extreme environments and emerging fields, providing critical support for the global energy transition.