Almost all nanocrystalline transformers are wound by complete machine manufacturers themselves. Different companies have different inverter circuit designs, different understandings of nanocrystalline cores, and different mastery of transformer making processes. As a result, transformers they make vary greatly in quality. Making high-frequency transformers is a key step in production. For this reason, some manufacturers hope to buy finished high-frequency transformers from professional suppliers instead of making them in-house.
High frequency transformers ferrite cores working at 20kHz to 50kHz , mostly U-type or EI-type, with a small number of O-type cores. U-type and EI-type cores are structurally hard to cut down transformer leakage inductance.
With the advantages of nanocrystalline cores, they become ideal materials to make smaller, more efficient high-frequency transformers, and help create a new structure for high-frequency transformers.
One patented design is named “Beetle” transformer. After further improvements, it became the patented “H-type” transformer. Both designs make full use of nanocrystalline cores’ features: high permeability, high magnetic flux density, low power loss and low magnetic leakage of ring cores. They adopt new primary and secondary winding structures. The metal shell protecting the core works as the secondary winding, fitting high-current output. The primary winding is wrapped evenly over the secondary winding, bringing very low leakage inductance. The fixing support and current output part are combined into one structure for better heat dissipation.
Advantages of this transformer:
High power: 10 kW ~ 20 kW, power density reaches 15 kW ~ 20 kW per kilogram
Low leakage inductance: normally below 5 μH, top versions less than 2 μH
High efficiency: over 99%
Small size and light weight: a 15 kW transformer weighs 3 kg, with dimensions 160×150×95 mm
Nice appearance
Due to special structure and complicated processing, this transformer has a relatively high price. It is now moderately used in electroplating and electrolysis power supplies, such as photovoltaic inverters, energy storage PCS, grid-tied inverters, off-grid inverters, main high-frequency transformers for energy storage, string inverters, commercial & industrial energy storage power supplies, residential energy storage systems, and nanocrystalline filter inductance cores for energy storage. It is hard to widely promote it in industries with fierce price competition. Therefore, the Ω-type transformer was developed.
The Ω-type transformer shares the same basic structure as common ring transformers, but with improved winding methods to lower leakage inductance and distributed capacitance. Its leakage inductance is generally below 10 μH. Its price is around 40% lower than Beetle-type or H-type transformers, attracting many manufacturers thanks to its good cost-performance.
Mass production of nanocrystalline transformers makes good use of the properties of nanocrystalline soft magnetic materials. It helps mass production and standardization of high-frequency power transformer cores, improves transformer efficiency and overall performance, and raises production efficiency for inverter welding machines, electroplating, electrolysis and other equipment. Several manufacturers are capable of producing such transformers at present. Some complete machine manufacturers have started to adopt Ω-type transformers for integrated production, which is an efficient, cost-saving and productive solution.
Email: sales008@mycoiltech.com
Name：Alex~Mycoiltech
