Design that Enhances performances

KPEL has in house Design skills to customize a transformer for particular specifications which enables the flexibility to offer transformers to wide variety markets in terms of Design.

Design activity is continuously reviewed as per ISO 9001 requirements during periodic internal and external audits

KPEL utilizes latest design automation tools including 3D modeling. Our design software optimizes by running thousands of iterations and selecting the lowest cost design enabling us to offer the lowest total cost of transformer to our customers.

CRGO Core Laminations with step LAP

Use of step lap core design which results in reduced magnetizing current, noise level and no load losses.

CORE is constructed from lamination of cold rolled grain oriented ( CRGO), Low loss Electrical steel, Feathering excellent magnetic properties. Slit coils confirming to international standards are surrounded from reputed mills. The individual stamping are coated on both sides with insulating material that is both oil and temperature resistance. The lamination are assembled in jigs tapped ad clamped in such a way so as to reduce vibration and inherent noise to a minimum.

Core Stacking in process
step lap lamination built core
step lap Lamination cut on CNC core  cutting Line

Amorphous Core Transformers

Amorphous Metal Distribution Transformer (AMDT) from KPEL represents the ultra – Low loss design solution, delivering the highest efficiencies. Amorphous metal – A technological advantages amorphous metal (AM) enables a significant reduction in no load losses as compared to CRGO.

KPEL has in house automated core manufacturing line and is among handful of companies with such capability.

Losses in Amorphous core Material

Amorphous core material (AM) offers both reduced hysteresis loss and eddy current loss because this material has random grain and magnetic domain structure which results in high permeability, which ensures a narrow hysteresis curve compared to conventional CRGO material. Eddy current losses are reduced by the high resistivity of the Amorphous material, and the thickness of the film.

The laminations comprises thin ribbons and the thickness of the sheet is about 1/10th that of the CRGO, i.e approximately 0.025 to 0.030mm. Amorphous Core Transformers offer 70 to 800% reduction in no-load losses compared to Transformers using CRGO core material. KPEL draws immense cost advantages due to iys in house Amorphous core facilities.

Amorphous Metal Distribution Transformers (AMDT), are REPAIRBLE as equally as CRGO Transformers, and easily serviced by our skilled services team at site or at our works.

Core Stacking in process
step lap lamination built core
step lap Lamination cut on CNC core  cutting Line
step lap Lamination cut on CNC core  cutting Line

Windings

Windings are designed for thermal, electrical and mechanical stresses. Typical pictures types of windings are generally adopted

LV Foil Wound Coils

The art of winding can be dramatically advanced by the foil windings. Copper&Aluminum sheet especially for high currents and low voltage windings. These windings are designed with special diamond dotted paper insulation between layers. Foil windings are best preferred to reduce the axial forces under fault conditions results in better ability to withstand a short circuit force /current. The greater winding efficiency of foil allows a 50% increase in the power output of a given core when compared to round/rectangular conductors. In the alternative transformer can put out the same power without overheating. The lower core cost of this transformer will offset the higher cost of Foil Winding.

HV Coils

High voltage coils are generally with round/rectangular strips with PVA covered or paper covered insulations. Windings or coils are made from high quality electrolytic grade copper/aluminum conductors sourced from reputed manufacturers. The windings are concentric circular or elliptical or rectangular in shape based on the design. Various types of design constructions namely layer, crossover, disc, etc are adopted.

step lap lamination built core
Core Stacking in process
step lap Lamination cut on CNC core  cutting Line