Innovative Amorphous Alloy Transformer Manufacturing Process: Core Technology for High Efficiency, Energy Saving, and Reliability

With the increasing global demand for energy efficiency and the continuous upgrading of power infrastructure, transformers, as key equipment in power transmission and distribution systems, are receiving increasing attention for their energy efficiency performance. Among numerous energy efficiency improvement technologies, the manufacturing process of amorphous alloy transformers stands out, becoming an important direction for energy-saving transformation in the industry. Wuxi Shuhong Technology Co., Ltd.'s independently developed amorphous alloy transformer manufacturing process provides an efficient and reliable solution for modern power systems through precise manufacturing processes and strict quality control.

Amorphous Alloy Material Characteristics and Process Fundamentals

Amorphous alloy is a new type of magnetic material prepared through rapid cooling technology. Its atomic arrangement is disordered, in stark contrast to the ordered crystal lattice structure of traditional silicon steel sheets. This unique microstructure gives amorphous alloys extremely low hysteresis loss and eddy current loss characteristics. In the manufacturing process, the fragility of amorphous alloys requires special processing methods, including precise surface coating technology and strict anti-fragmentation control measures.

Wuxi Shuhong Technology's amorphous alloy process documentation details the entire process from core treatment to finished product assembly. The core surface is coated with epoxy resin. This step not only enhances the structural strength of the core but also provides necessary insulation protection. The coating process needs to be carried out in a temperature-controlled environment to ensure uniform resin coverage and complete curing, reflecting the strict requirements of the process on the production environment and control accuracy.

Precision Control of Coil Manufacturing Process

The performance advantages of amorphous alloy transformers largely depend on the precision of coil manufacturing. The company's process documentation details the production processes for low-voltage foil-wound coils and low-voltage wire-wound coils. In the manufacture of foil-wound coils, the process requires precise verification of the straightness and dimensions of the copper foil, and winding is performed using a dedicated foil winding machine under preset tension. The alignment of interlayer insulation and conductors, winding tightness, and the geometric shape of the coil all require real-time monitoring and adjustment.

The manufacturing process of high-voltage wire-wound coils is even more complex, involving the precise extraction of tap leads and special treatment when the number of turns is not a complete layer. The process documents clearly stipulate that the tap leads must be routed from the narrow side of the coil, with the spacing between adjacent tap leads controlled at approximately 30mm, and clearly marked. These detailed requirements ensure the electrical performance and long-term operational reliability of the coil.

Transformer Body Assembly and Vacuum Treatment Process

Transformer body assembly is a critical step in the manufacturing of amorphous alloy transformers. Due to the extreme fragility of amorphous alloy materials, special care is required during the opening, assembly, and closing of the core. The process documents stipulate that a special protective cover must be installed immediately after the core is opened, and the open end must be protected with adhesive tape to minimize the generation of amorphous fragments.

Vacuum drying and vacuum oil filling processes are crucial for the insulation performance of the transformer. The transformer body needs to be dried under strictly controlled temperature curves to ensure that moisture in the insulating material is completely removed. The vacuum oil filling process requires a specific vacuum level, with the oil filling speed controlled at approximately 8L/min, to ensure that the transformer oil fully penetrates all insulation gaps and eliminates internal air bubbles.

Performance Advantages Brought by Process Innovation

Transformers manufactured using Wuxi Shuhong Technology's amorphous alloy process demonstrate significant advantages in no-load loss. Compared with traditional silicon steel transformers, the no-load loss can be reduced by 60%-80%, which means huge energy savings for distribution transformers operating under light load or no-load conditions for extended periods. The strict cleanliness control and insulation treatment in the process also greatly improve the product's short-circuit resistance and operational reliability.

Industry Impact and Sustainable Development

With the increasing global demand for energy conservation and emission reduction, the market demand for amorphous alloy transformers continues to grow. Wuxi Shuhong Technology's amorphous alloy production process not only meets current energy efficiency standards but also prepares for future, more stringent environmental requirements. The company's complete process document system ensures the standardization of the production process and the consistency of product quality.

In the future, the amorphous alloy process will continue to develop towards intelligence and automation. By introducing advanced testing equipment and digital control systems, production efficiency and product qualification rates will be further improved. At the same time, the research and development of new materials and processes will drive amorphous alloy transformers towards higher energy efficiency and lower costs.

Conclusion

Wuxi Shuhong Technology's amorphous alloy transformer manufacturing process represents a significant advancement in China's high-efficiency power equipment manufacturing sector. From material processing to finished product assembly, every step reflects a rigorous pursuit of quality and relentless efforts in technological innovation. This complete production process not only provides reliable and energy-efficient products for the power industry but also offers valuable insights for the transformation and upgrading of China's manufacturing industry. With the continuous maturation of the technology and its increasingly widespread application, amorphous alloy transformers are bound to play an even more important role in the global energy transition.