What are the Causes and Prevention Methods for Positive Tolerance Exceeding on Both Sides of the Maximum Diameter of the Core？

Content

●Cause Analysis

a) Thickness Deviation During Core Stacking:

During the core stacking process, if the thickness of the laminations in each layer is generally thicker, it will directly result in the overall thickness and diameter of the core exceeding the specified tolerance. This typically occurs due toinconsistencies in lamination thickness during manufacturing or handling, or a lack of effective thickness control during stacking.

b) Misalignment of Core Laminations:

If the laminations of the core exhibit significant left-right misalignment, it will lead to an irregular geometric shape of the core, causing the measurement of the maximum diameter to exceed the positive tolerance. This misalignment may be caused by inaccurate positioning or improper operation.

c) Inadequate Clamping of the Core:

After the core stacking is completed, if the core is not effectively clamped, it can deform or shift during subsequent processing or testing, thereby affecting measurement results and causing the measurements on both sides to exceed the positive tolerance.

●Preventive Measures

a) Strict Control of Core Stacking Thickness:

During core stacking, the thickness of each layer of laminations must be strictly controlled. Typically, the thickness tolerance of each core layer is required to be±0.5mm, and positive tolerance is not allowed to occur simultaneously in three consecutive layers. This can be achieved by regularly calibrating the thickness measuring tools for laminations, optimizing the lamination manufacturing process, and implementing stringent quality control measures during stacking.

b) Ensuring Symmetry of Core Laminations:

During the core stacking process, strict control over the symmetry of the laminations on both sides of each layer is necessary. Precise positioning devices and alignment tools should be used to ensure that each layer of laminations is accurately aligned toprevent left-right misalignment. This can be accomplished by optimizing the positioning and alignment process of the laminations and regularly checking and adjusting for symmetry.

c) Adequate Clamping and Improved Binding Process for the Core:

After the core stacking is completed, the core should be adequately clamped immediately to prevent deformation during processing or testing. The accuracy of the core binding process should be improved by using appropriate clamping tools and binding materials, ensuring that the core does not bulge after binding. Regular inspections of the clamping equipment are necessary to ensure its proper functioning, and the binding process should be monitored and adjusted to prevent uneven clamping or looseness.

In summary

By implementing the aforementioned measures, the issue of positive tolerance exceeding the measurements on both sides of the core's maximum diameter can be effectively prevented, ensuring that the geometric dimensions of the core meet design requirements, thereby enhancing the performance and reliability of the transformer.

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LuShan, est.1975, is a Chinese professional manufacturer specializing in power transformers and reactors for 49 years. Leading products are single phase and three phase isolation transformers, electrical transformer, distribution transformer, step down and step up transformer, low voltage transformer, high voltage transformer, control transformer, toroidal transformer, R-core transformer; DC inductors, AC reactors, line and load reactor, chokes, filtering reactor, and intermediate, high-frequency products. Our power transformers and reactors are widely used in 10 application areas: rapid transit, construction machinery, renewable energy, intelligent manufacturing, medical equipment, coal mine explosion prevention , excitation system, vacuum sintering(furnace), central air conditioning.

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