AEM Brochure

A CORE PART OF:

EFFICIENT ENERGY DISTRIBUTION

INNOVATING TRANSFORMERS

YOUR OPERATIONAL SUCCESS

3Unicore products .......................................................................................................................................................................... 10

UCM3000 .................................................................................................................................................................................... 10

UDM4000 ....................................................................................................................................................................................11

DUO Core ....................................................................................................................................................................................12

Single Phase ........................................................................................................................................................................12

Three Phase .........................................................................................................................................................................13

Distributed Gap Cores ...........................................................................................................................................................13

Cruciform ...................................................................................................................................................................................14

Stepbutt ......................................................................................................................................................................................14

Butt-2 Core & Butt-3 Core .....................................................................................................................................................15

Gapped Core .............................................................................................................................................................................16

Uncut Core .................................................................................................................................................................................16

Dee Core .....................................................................................................................................................................................17

Straight Laminations ..............................................................................................................................................................17

Unicore manufacturing examples ...........................................................................................................................................18

Assembly of Unicores ...................................................................................................................................................................19

Single Phase DUO Core .........................................................................................................................................................19

Three Phase DUO Core ......................................................................................................................................................... 20

Single Phase Distributed Gap ............................................................................................................................................ 21

Cruciform .................................................................................................................................................................................. 22

Examples of transformers .......................................................................................................................................................... 23

Customer references ................................................................................................................................................................... 26

Unicore Customers ................................................................................................................................................................ 26

Agents ........................................................................................................................................................................................ 27

Contents

UNICORE CATALOGUE ThE RANGE AND ThE FACTS

4Since 1958 AEM has been driven by the vision to improve the efficiency of transformer core technology

throughout the entire value chain. This means better manufacturing machines, better core products and better performance in the field.

With the cleantech age upon us, our original ideals have proven to be far ahead of the times. AEM is firmly

committed to continue as a leader in highly efficient core technologies.

Generating efficiency in 3 key areas

Reduce manufacturing foot print and delay investment into larger machines

Easy and affordable design, assembly and manufacture

Proven performance to improve distribution efficiency

INTRODUCING OUR CORE VISION

CORE MANUFACTURING

UNICORE PRODUCTS

IN ThE FIELD

5A CORE PART OF ThE BIGGER ISSUES

Climate change is driving economies and technologies to be more efficient, eliminate waste, reduce carbon emissions and provide sustainability.

Whether you believe in climate change or not, is not the issue. Carbon emission schemes and taxation will affect believers and non-believers alike, we will all pay, and hence must play a part.

AEM has been producing high quality cores and core machines long before the term carbon credits was created. Our core value is to vastly improve efficiencies throughout the significant value chain that has been our focus since 1958.

Our Unicore products and manufacturing machines are now the preferred choice for many small, medium and multinational transformer manufacturers world wide. With such significant acceptance, we see the opportunity to enhance our part in the energy industry.

Helping you play an even bigger part in the overall energy and cleantech solution.

6Unicores hold a number of advantages over other types of magnetic cores for general purpose and distribution transformers. With lower loss, efficient production and ease of assembly, our Unicores have helped innovate transformers around the world.

The gap has widened even further with the DUO core, which not only provides exceptional energy efficiency, it is also very simple to assemble. The future for DUO core will be to replace large E&I, strip laminations and C cores, which struggle to meet the need for greater energy efficiency.

Our comprehensive range of UnicoresEach type is able to be customised and made to exacting specifications.

DUOcore

Distributedgapcores

Cruciform

Stepbutt

Buttcores

Gappedcore

Uncutcore

Singlephase

Threephase

For General Purpose and Distribution Transformers our core products have enhanced efficiency in many ways

Must be the most efficientin terms of

reducing core loss

Must perform with low loss and affordability

Must be easy to use, install and handle

OUR EXPERTISE hAS DEVELOPED A RANGE OF UNICORES,BASED ON ThREE kEY CRITERIA:

A CORE PART OF INNOVATING TRANSFORMERS

7Typically used for distribution and general purpose transformers from 1000 VA to 1500 kVA or more.

Weight: Up to 1500kgUnicore faces: Distributed gap, DUO core, straight butt or uncutCorners: 30, 45, 90 - depending upon applicationSimple to specify and produce to suit your design.

Produced from any grade of Grain Oriented Silicon Steel (GOSS). Thickness from 0.2 to0.35 mm. Strip width from 20 to 300 mm.

A CORE PART OF INNOVATING TRANSFORMERS

ParametersWindow Length (WL)Strip Width (SW)Strip Thickness (ST)

Window Width (WW)Build-up (BU)Corner Angle

GEOMETRY & SIZES

MATERIALS

Build-up

Window Length

Strip Width

Window Width

PERFORMANCE

8In fifty years we have gone from a manufacturer of arc welders to a leading global supplier of Unicore machines and Unicores. The one thing that has been common throughout the journey has been the question, how to improve efficiency at each and every step?

The small size of the Australian transformer core market inspired AEM to develop flexible automated machinery for core manufacture. The company was also committed to innovating core design.

The result has been the creation of Unicore machines that produce the exceptional Unicores. Unicores are highly regarded in the market as the most advanced and efficient available. And the machines themselves

are prime examples of improving efficiency.

Over 200 Unicore machines sold globallyUnicore machines eliminate the need for fixed tooling such as jigs and mandrils. Unicore laminations are fully formed by the machine.

For the operator, flexibility, accuracy and reliability are key advantages. Reduced core/coil assembly time results in reduced transformer costs.

The lasting passion for continual efficiency that began in 1958

Fullyprogrammableforflexibleproduction

Producefullyformedcores

Eliminatemanualforming

Reducesneedforannealing

Minimisescoreloss

Automated,withnotoolingrequired

Just-in-timeproductionruns

Convenienceofsmallersize,lessweight

Superiorproduct,withsameaffordability

Easiertohandleandstore

AEMUnicoremachineshaveminimalfootprint

Theyarehighlyaffordable

Requireminimalinventory

Multiplemachinesvastlyincreaseproduction

capacity for far less cost Delayextensivecapitalinvestment

MANUFACTURING hIGh qUALITY CORES hAS NEVER BEEN EASIER

BEFORE YOU BUY A LARGE EXPENSIVE CORE MAChINE...

A CORE PART OF YOUR OPERATIONAL SUCCESS

9Simple and flexible productionThe core design screen offers a simple GUI for operators to make selections, configure and produce at a rate that suits your requirements

High speedproduction forJust-in-TimeperformanceA spreadsheet is available to calculate core production times.

Reduce annealing costsUnicores are fully formed by the machine.

Annealing will reduce core loss on small to medium sized cores but costs can be saved if this is not necessary. Large Unicores have very low loss, so annealing costs can be saved. ROI can be as low

as 6 to 9 months

A CORE PART OF YOUR OPERATIONAL SUCCESS

UCM3000AEM UNICORE UCM3000

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FOR GENERAL PURPOSE AND DISTRIBUTION TRANSFORMERS

DescriptionIn the 10 years since its introduction Unicore technology has been proven and accepted in over 30 countries worldwide.

From small specialists to large multinationals, Unicore is the preferred technology.

UDM4000UCM3000 AEM UNICORE UDM4000

UNICORE PRODUCTS

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Hydraulic Expansion Mandrel Non-contact Induction Sensors Typical Installation

Description

Suitableformostindustriesrequiringdecoilers

Pushbuttonhydraulicexpandingmandrel

Maximumcoilwidth450mm

Maximumcoilweight2000kg

Maximummandreldiameter525mm

Minimummandreldiameter460mm

Speedrange5-30rpmbyVFdrive

Stripsensingnon-contactinductionsensor

Power380-5000VAC3ph

CanbepoweredfromtheAEMUnicoremachine

SINGLE PHASE

DUO CORE

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Optional AnnealingAnnealing reduces losses by 5 to 30%, depending on the core size.

No BandingSimple TIG weld of final lamination only.

ApplicationDUO core is the newest type of Unicore. It is a low loss, price competitive core with very easy assembly. It is used for core-type, single-leg and shell-type, single and 3-phase Distribution and General Purpose Transformers. Annealed DUO cores with one lamination per overlap will have the lowest core loss. After assembly into windings TIG welding of the last lamination and wedging is recommended.

DUO Core TypesTo reduce assembly time, the number of laminations per overlap may be increased from 1 up to 3. Increasing from 1 to 2 results in a 45% decrease in assembly time, and 2 to 3 results in a further 25% decrease. Note that losses and magnetising VA will increase.

MaterialAny grade of GOSS, thickness 0.2 to 0.35 mm.

DescriptionDUO Core is very suited to Core Type Single Phase Transformers. When used for Shell Type, the core leg outside the coils should be held tight.

DUO CORE

Dimension Minimum (mm) Maximum (mm)

Window Length (WL) 80 Unlimited*

Window Width (WW) 40 Unlimited*

Strip Width (SW) 20 (with two strips) 300 (with one strip)

Build Up (BU) Material Thickness Unlimited*

DUO Sizes

* Not limited by the Unicore machine. Limited only by practical transformer manufacturing considerations.

SINGLE PhASE

DISTRIBUTED GAPSINGLE PHASE

THREE PHASEDUO CORE ThREE PhASE

Dimension Minimum (mm) Maximum (mm)

Window Length (WL) 60 Unlimited*

Window Width (WW) 40 Unlimited*

Strip Width (SW) 20 (with two strips) 300 (with one strip)

Build Up (BU) Material Thickness Unlimited*

DG Unicore Sizes

* Not limited by the Unicore machine. Limited only by practical transformer manufacturing considerations.

DISTRIBUTED GAP CORES

DescriptionDUO Cores are very well suited to Evans style (Core Type) Three Phase Transformers. They are also very good for the inner cores of a 4 core / 5 limb transformer.

ApplicationDG Unicores represent a family of cores with a single cut per lamination. They are used for single-leg and shell type, single and 3-phase Distribution Transformers.Unlike traditional technology of producing DG cores, notooling is needed for production of DG Unicores.

DG Unicore TypesThere are several different types of DG Unicores, namely a core with straight cut face, Diverging face (cascade of cut faces fans out) and End-Overlap (spirally wound laminations) face. The position and specification of the DG face can be easily programmed.

MaterialAny grade of GOSS, thickness 0.2 to 0.35 mm.

Optional AnnealingAnnealing reduces losses by 5 to 30% depending on the core size and is almost always desirable to achieve the highest efficiency.

UNICORE PRODUCTS

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STEPBUTT

CRUCIFORMDescriptionFor use with round coils a Unicore may be made from multiple strip widths. The resultant core legs have a cruciform cross section.

DescriptionThis type of Unicore is used only for a shell type General Purpose Transformers to replace laminations, up to approx. 2 kVA. Its losses are much higher than DUO or DG Unicores, lower than or comparable to a C core but much lower than laminations.

CRUCIFORM

STEPBUTT

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STEPBUTT

BUTT CORESCRUCIFORM BUTT-2 CORE AND BUTT-3 COREDescriptionThese cores have a gap of programmable size in 2 (single phase) or 3 (3-phase) legs. They are used in chokes and reactors.

UNICORE PRODUCTS

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UNCUT CORE

GAPPED COREDescriptionIt is a Single Phase core with one gap of programmable size in one leg only.

GAPPED CORE

DescriptionIt is a core with no cuts. The Unicore machine is only feeding and folding steel.Uncut cores are used for Current and Voltage Transformers. They are always annealed to achieve the lowest loss and magnetising current.

UNCUT CORE

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STRAIGHT LAMINATIONSUNCUT CORE

DEE COREGAPPED COREFOR VOLTAGE TRANSFORMERS

DescriptionDG core with unequal corner sizes promotes uniform shrinkage of resin, reducing the likelihood of voids forming.

DEE CORE

DescriptionThe Unicore machine can be programmed toproduce rectangular 90 cut laminations whichcan be used for the manufacture of chokes andtransformers.

STRAIGhT LAMINATIONS

UNICORE PRODUCTS

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Therma FM, Czech Republic

Makitel, Macedonia

INTEPS, RussiaVakar, Czech Republic

MANUFACTURING

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MANUFACTURING EXAMPLES

MANUFACTURING

SINGLE PHASE

19

ASSEMBLY OF UNICORES

Procedure1. Insert the first full size inner lamination into the coils.

2. Insert the smallest male packet.

3. Insert the helper strips.

4. Insert the corresponding female packet and then remove the strips.

5. Now repeat the steps 2 to 4 until all packets including the last female half with the outer welding lamination have been inserted.

6. After welding the outer lamination an insulation material may be used to lightly wedge the remaining space between the core and the coil.

SINGLE PhASE DUO CORE ASSEMBLY

Core size: WL 210, WW 60, SW 70, BU 60 mmCore weight: 21 kg Transformer power: 7.5 kVACore production time: 18 min Core assembly time: max 4 min

The disassembled core Female half of the core Partly assembled core without bobbins

DUO3 detail

Assembly platesMale half of the core Taking a male packet Taking a female packet

THREE PHASE

20


ProcedureAssembly of a three phase DUO core is very similar to the single phase assembly. Start with assembly of the first inner core into the coils. After the second inner core is assembled insert an insulation material to wedge the inner cores apart so that the first outer male packet fits accurately. Last lamination of the inner cores may be welded. Now insert the outer core and wedge firmly in the outer coils. Then weld.

Example of a Cast Resin TransformerCore weight: 164 kgTransformer power: 50 kVACore production time: 41 minCore assembly time: approx. 50 min

An assembly table First inner core assembled

Inserting first lamination

Start of outer core assembly

Inserting female packet

Strapping the core Wedging the inner cores

ThREE PhASE DUO CORE ASSEMBLY

SINGLE PHASE

21


25 kVA Core Type Dry Transformer With DG CoreCore size (DG): WL 300, WW 160, SW 130, BUP 67Core weight: 73 kgCore production time: 21 minCore assembly time: approx. 45 min

SINGLE PhASE DISTRIBUTED GAP CORE

CRUCIFORM

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CRUCIFORM CORE ASSEMBLY

100 kVA Distribution Transformer With DUO2 CoreCore size: WL 345, WW 120, SW 55/75/105/120/135/145, BUP

138Core weight: 284 kgCore assembly time: approx. 60 min

25 kVA Dry Distribution Transformer With DDG CoreCore size (DDG): WL 280, WW 128,

SW 60/90/120, BU 116mmCore weight: 152 kgCore production time: approx. 70 minCore assembly time: approx. 60 min

TRANSFORMERS

UNICORE PRODUCTS

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EXAMPLES OF TRANSFORMERS

DISTRIBUTION TRANSFORMERS

Three phase 100 kVA transformer, Poland

4-core 5-limb 3-ph transformer, Australia

100 KVA transformer, Italy 10 mVA transformer, South Africa

TRANSFORMERS

24


GENERAL PURPOSE TRANSFORMERS

Shell type transformer with DUO cores, Russia

Core type transformer

Single-leg transformer

TRANSFORMERS

UNICORE PRODUCTS

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VOLTAGE / POTENTIAL TRANSFORMERS

Shell-type DUO core transformer, Italy

Medium voltage transformer

UNICORE CUSTOMERS

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CUSTOMER REFERENCES

Australia & New ZealandABB Australia Pty Ltd, Darra, New South WalesAEM Cores Pty Ltd, Gillman, South AustraliaETEL Distribution Transformers, Auckland, New ZealandThycon Industries Pty Ltd, Coburg, VictoriaTyree Transformers, Mittagong, New South Wales

AsiaETAH Sdn. Bhd., Kuala Lumpur, MalaysiaHan Chang Transformers, Korea

IndiaAlfa Transformers Ltd, Gujarat, IndiaAlfa Transformers Ltd, Orissa, IndiaB.R. Industries Ltd, New Delhi, IndiaDanishPrivateLimited,Jaipur,IndiaDanke Products, Gujarat, IndiaEast India Udyog Ltd, Uttar Pradesh, IndiaGenusOverseasElectronics,Jaipur,IndiaHuphen Transformers, Maharashta, IndiaJupiterElectricals,Gujarat,IndiaKalpanaIndustries,Jhunjhunu,IndiaKotsons Pty Ltd, Agra, IndiaKryfs Power Components Limited, Mumbai, IndiaMangalElectricalIndustries,Jaipur,IndiaManu Power Equipments Pty Ltd, Hyderabad, IndiaNeptune Stampings, Gujarat, IndiaNucon Switchgears Pty Ltd, Punjab, IndiaPatson Transformers Pty Ltd, Gujarat, IndiaPME Transformers (India) Limited, Uttar Pradesh, IndiaRTS,Jaipur,IndiaSangrur Industrial Corporation, Punjab, IndiaShirdi Sai Laminations, Andhra Pradesh, IndiaShriKrsnaSudarshanUrjaPtyLtd,Jaipur,IndiaSPI Containers, Gujarat, IndiaStar Delta Transformers Ltd, Bhopal, IndiaSVR Electricals (P) Ltd, Andhra Pradesh, IndiaSwastikCopper(P)Ltd,Jaipur,IndiaTechnical Associates Ltd, Uttar Pradesh, IndiaUttam(Bharat)Electricals(P)Ltd,Jaipur,India

AfricaAlloy Magnetic Cores, Elsburg, South AfricaAreva,Johannesburg,SouthAfrica

North AmericaABBInc,JeffersonCity,Missouri,USAAmbar Electroingenieria, Ecatepec, MexicoBCL Magnetics, Burlington, Ontario, CanadaCarte International, Winnipeg, CanadaCentral Moloney Inc., Pine Bluff, Arizona, USACG Power Systems USA Inc, Washington, MissouriCogent, Ontario, CanadaCorte de Nucleos, Temoaya, MexicoEaton Electrical, Arden, North Carolina, USAEl-Met-Parts, Dundas, Ontario, CanadaIEM/Condumex, Tlalnepantla, MexicoInstrument Transformers, Clearwater, Florida, USAJaroElectronics,Basseterre,StKittsLakeView Metals Inc., Winthrop Harbor, Illinois, USAPower Magnetics, Gardena, California, USAProlec GE, Apodaca, MexicoTC Metals, City of Commerce, California, USATransformadores IMEM, Celaya, MexicoVicksmetal, Vicksburg, Mississippi

South AmericaCaivet Transformadores, Caracas, VenezuelaCNS, Sao Paulo, BrazilCorporacion Iadiexport, VenezuelaEcuatran SA, Ambato, EcuadorFrana International Ltda., Bogota, ColombiaINATRA, Guyaquil, EcuadorRhona S.A., Vina Del Mar, ChileRymel Engenieria Electrica, Itaqui-Autoquia, ColombiaSiemens, Bogota, Colombia

EuropeALCE Elektrik, Pendik, TurkeyArcelorMittal, Frydek-Mistek, Czech RepublicElektromashina, Kemerovo, RussiaElesa Trasformadores, Zarautz, SpainINTEPS, Pskov, RussiaMakitel, Ohrid, MacedoniaMetod, Sobinka, RussiaPskovelektrosvar, Pskov, RussiaRussian Transformer, Samara, RussiaStalprodukt, Bochnia, PolandTherma FM, Przno, Czech RepublicTraser, Serravalle Scrivia, ItalyVakar, Dobra, Czech RepublicZucchiatti Elettromeccanica, Pordenone, Italy

UNICORE CUSTOMERS

UNICORE CUSTOMERS AGENTS

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AGENTS

Head OfficeAEM Cores Pty Ltd95B Bedford StreetGillman, South Australia 5013T: +61 8 8341 0086F: + 61 8 8341 0225E: [email protected]: www.aemcores.com.au

North AmericaUnicore Machines (USA) LLC20 Hoiles Drive, Unit B, Right Side,Kenilworth,NewJersey07033USAT: +908 245 0566F: +908 245 1770E: [email protected]

India, Bangladesh, Pakistan, Sri LankaAEM Unicore Machinery IndiaA-186 Telephone Exchange LaneMahipalpur, New Delhi 110037 IndiaT: +91 11 41019214/26784948F: +91 141 26781405E: [email protected]

South AmericaFrana International Ltda.Cra. 127 No. 15B-40 Interior 4 Bodega 4Bogota, ColumbiaT: (571) 298 6852-298 6791E: [email protected]

JapanKisco Ltd2-9-25Tatekawa,Sumida-Ku,JapanT: 03 5600 6222F: 03 5600 6226E: [email protected]

AfricaAlloy Magnetic Cores (AMC)Cnr. Simon Bekker & Crompton StreetGermistonSouth,Johannesburg,SouthAfricaT: +27 11 825 1010F: +27 11 825 1045E: [email protected]

EuropeAEM EuropeTyrova 1033, 744 01 Frentt p.R.Czech RepublicT: +420 608 834 747E: [email protected]

Technical Consultant for Cast Resin and Oil Type Distribution TransfornerMr. Ergin Dikmen, TurkeyE: [email protected]

Subagents in Europe

Austria, Germany & SwitzerlandSchpppi IndustrievertretungenGeissweidli 5CH-8846 WillerzellT/F: ++41 55 422 00 40T: ++ 41 79 620 35 47E: [email protected]

RussiaTC WindeqDomodedovskoe shosse, 1/3Moscow 142116T: +495 543 72 60F: +495 542 20 85E: [email protected]

SpainMP-TECNOIMPORT, S.L.Nord, 76 Local 2008950 Esplugues de LlobregatT: +34 93 473 7975F: +34 93 473 7992E: [email protected]

TurkeyUYGAR Teknoloji MhendislikElektrik Makineleri San. Ve Tic. Ltd. Sti.1420 Sokak No: 30/1-135220 Kahramanlar-IZMIRT: ++90 232 445 51 62F: ++90 232 445 51 63E: [email protected]

AGENTS

95B Bedford Street

Gillman South Australia 5013

T +61 8 8341 0086

F +61 8 8341 0225

[email protected]

www.aemcores.com.au

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