Copper Strip for Transformer Winding

 

With the development of the power industry, the capacity of a single transformer is increasing day by day. Therefore, the power industry proposes improvement requirements for the structure of transformers in accordance with the principles of increasing capacity, saving materials, improving labor productivity, reducing costs, and reducing usage volume, in order to improve the operational efficiency and reliability of transformers.copper strips for transformer is megatrends Traditional transformers use wire winding structures (oil immersed transformers), while transformers with strips winding structures made of pure copper strips (dry transformers) have extremely high dynamic and thermal stability, especially in short circuit conditions;High space utilization rate; The manufacturing process is simple and can be automatically wound, making it easy to achieve mechanized production with high winding efficiency; Uniform heat distribution, small volume, light weight, large capacity, material saving, good energy-saving effect, low no-load loss, good heat dissipation performance, easy welding, no axial force, long service life, no pollution, lifelong maintenance free, and many other advantages have been widely used in transmission and distribution engineering, and will gradually replace transformers with wire winding structures.

Correspondingly, copper strips for transformer used for high-voltage windings are called high-voltage strips, and copper strips used for low-voltage windings are called low-voltage strips. At present, there are dry-type transformers that use copper strips for transformer winding on both high and low voltage sides, as well as dry-type transformers that use copper wire on the high voltage side and copper strips on the low voltage side. Copper strips is also used for winding the low-voltage side of oil immersed transformers.

 

 

 

 

Our technical experts have long time experience in copper strip slitting and edging. We fitted state of art machines for processing, we have a total solution for strips edging system. The copper strip edge is excellent to meet the requirements of transformer.

 

 

●Giner has powerful raw material sourcing channel.

●7S management of the total QC control.

●Huge stock can meet the all kinds of customer's requirement.

●On time delivery.

●100% Qualified rate.

 

 

Ductility and Malleability: Copper wires can be easily pulled or twisted and, therefore, can be easily fitted in areas or corners that are hard to reach. Besides, copper wires are malleable. They are soft and can be easily shaped and manipulated. They do not break easily under pressure. All these properties ensure a smooth installation of electrical wires.

 

High Electrical Conductivity: Copper has high electrical conductivity. In fact, the electrical conductivity of copper is the highest among all non-precious metals. This property makes copper strips the preferred material for many electrical appliances.

 

High Thermal Conductivity and High Melting Point: Copper is a good conductor of heat. It allows heat to pass through it easily and therefore copper strips are a great choice for electrical appliances that tend to generate a lot of heat. Copper also has a high melting point. High melting point ensures the wires do not burn at very high temperatures and the electrical appliances remain secure. It means if you are using wires with copper strips, you don't need to worry about electrical fluctuations or fire hazards.

 

Corrosion-resistance: Copper is resistant to corrosion. It does not rust or oxidize. For this reason, bare copper wires find extensive application in marine appliances.

 

Compatibility: Majority of the electrical manufacturers prefer using bare copper strips in appliances. So if you are installing wires at homes, use copper to maintain compatibility. Using wires of any other material can lead to galvanic reactions and therefore prove to be dangerous. So it is better to avoid risks and use copper.

 

Durability: Bare copper strips are also durable and last long. So if you are installing copper wires, you do not need to worry about going for frequent repairs.

 

 

Stage 1: Melting Down Copper

Today, copper is typically melted down in an electric furnace known as an induction furnace where they are better able to reach and monitor the required temperature for melting this ore; copper has a high melting point of 1083°C (1981°F). Induction furnaces are extremely pricey industrial equipment, but they do ensure a level of safety that is not present in foundries that are self-built. Typically, copper is melted down by itself but, occasionally, other materials such as zinc may be added to create a copper alloy.

 

Stage 2: Laboratory Test

Next, blocks from each batch of copper are sent to a laboratory where they are inspected to guarantee that specific customer requirements and product specifications are met.

 

Stage 3: Cutting

After each batch is approved, it is formed into a copper strip. The entire copper strip is then placed on a cutting table, and cut off using a cutting wheel saw. Then the copper strip's uneven surface is smoothed using a copper strip surface washing machine, which is advantageous for the copper strip's later-processed surface for smoothness and flatness.

 

Stage 4: Hot Rolling

Next, the copper strip is heated at a temperature of 1,000 °C (1,832 °F), and then rolled to ensure a uniform thickness and create a more workable material.

 

Stage 5: Washing With Water

There are still surface impurities after the hot rolling process is applied to each copper block. As a result, it is first subjected to the sealing furnace and then the washing procedure is undertaken in order to prevent the completed product's quality from being impacted. Then, the dark red areas are eliminated by a fine metal brush during washing and the middle red sections on the copper strip's surface are washed away by the acidity in the washing pool.

 

The copper strip clearly sparkles following this round of treatments. However, there are frequently still red plaques, so it is critical to repeat the washing stage. The washing pool's acidity is regularly checked during the washing process and acid is added as needed in order to prevent the acid level from being too low and causing insufficient washing.

 

Stage 6: Rolling the Plate

Finally, the copper strip is heat treated and forged inside a sealing furnace, then processed to go from a rough to a fine material of specified size.

 

 

Features Differences

Aluminum strip has several advantages over copper strip. It is more resistant to corrosion and heat, which makes it suitable for outdoor use. The conductivity of aluminum is lower than that of copper at room temperature but increases as the temperature rises. This means that aluminum is more efficient at transferring heat than copper, making it ideal for electric heating elements and radiators.

 

Copper can be recycled many times without losing its properties, while aluminum loses its strength after several recycling cycles. Copper can be recycled indefinitely if there is no contamination in the mix; however, pure aluminum cannot be recycled because it corrodes easily when exposed to oxygen or water vapor in the air environment during melting process.

 

Cost Differences

Aluminum strips are relatively cheaper than copper strips. However, many China suppliers are offering a range of transformer winding materials at competitive prices.

 

Density Differences

Copper has a specific gravity of 8.9 and aluminum has a specific gravity of 2.7. This means that for every gram of aluminum you need 2.7 grams of copper to produce the same volume.

 

The density difference between aluminum and copper can be used to determine how much more material is required for an application using aluminum rather than copper. For example, if you need 100 pounds per square foot (psf) of insulation on your transformer core, then you would need approximately 133 psf if it were made with aluminum instead of copper because 2.3 times more material would be required by the transformer manufacturer in order to achieve the same amount of insulation when comparing their densities together.

 

Electrical Conductivity Differences

The resistivity of a material is the measure of its resistance to electric current. This property is important for transformers because it determines how much heat the material can withstand before melting or burning. The higher the resistivity, the more heat that can be dissipated without reaching unsafe temperatures.

• Aluminum strip has the electrical conductivity of above 60%IACS.


• While copper strip has the electrical conductivity of 99.80%IACS.

 

 

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