(1) Select high-quality materials to manufacture transformers
Transformers change the network voltage through electromagnetic induction. The main materials are silicon steel sheets and electromagnetic wires. The quality of these two materials directly affects the loss characteristics of the transformer. The loss formed by the transformer core during operation is generally called no-load loss. The loss value is constant and has little to do with the load rate of the transformer. It is also inevitable. However, the quality of the magnetic material can change the size of its loss. The first generation of energy-saving transformers used high-quality Q11 and Q10 cold-rolled grain-oriented silicon steel sheets, eliminated hot-rolled D44 and other silicon steel sheets, and combined with structural design improvements to reduce no-load torque loss by 40%.
(2) Optimize design and improve process
Improving the loss characteristics of transformers from the perspective of structural design and manufacturing process is the main research topic of manufacturers. The application of electronic computers in transformer design has opened up broad prospects for design work. Under the ideal ratio of copper (electromagnetic wire) to iron (silicon steel sheet), the design goal can be to minimize loss and minimize copper and iron consumption. High-quality materials and optimized curves intersect at a single point, achieving optimal results. Changing the core structure from straight seams to semi-straight, semi-slanted, and fully-slanted seams represents a breakthrough in structural design. This allows the magnetic conductivity of grain-oriented silicon steel sheets (the widely used Q10 and Q11 steel sheets) to be smoothed in the core seam area, reducing no-load losses.