Transformer performance depends not only on the grade of CRGO steel or lamination geometry but also on the precision of each cut. Even slight deviations in lamination size or burr thickness can cause uneven gaps, resulting in higher core losses, noise, and vibration. For power equipment that operates continuously for decades, accuracy in every cut is essential.
Here’s how dimensional accuracy directly affects transformer noise and vibration:
1. Reduced Air Gaps in the Core
When laminations are cut with inconsistent dimensions, small air gaps appear between sheets. These gaps disrupt the magnetic flux path, increasing no-load losses and causing uneven flux distribution. Precise cutting reduces air gaps, leading to smoother flux flow and quieter operation.
2. Lower Magnetostriction-Induced Noise
CRGO steel expands and contracts slightly when it experiences alternating magnetic fields, a phenomenon known as magnetostriction. If laminations are uneven, this expansion causes more vibration and the typical transformer “hum.” With accurate size control, the stacking remains uniform, significantly lowering magnetostrictive noise.
3. Controlled Vibration and Mechanical Stability
Vibration is not just a noise problem; it can loosen clamping bolts, speed up wear, and shorten transformer lifespan. Consistent lamination thickness and edge accuracy create a stable core stack that resists vibration, even under heavy loads.
4. Longer Service Life of Insulation
Vibration and noise often result in mechanical stress that ultimately affects insulation paper and oil systems. By maintaining tight dimensional tolerances, manufacturers reduce unnecessary mechanical strain, which helps insulation last longer and ensures reliable performance.
5. Energy Efficiency and Compliance
In modern grids, efficiency standards (such as BIS and BEE in India) require transformers to minimize losses. Accurate laminations help manufacturers meet these standards while keeping noise levels within acceptable limits.
Sarjani Coretech Advantage
At Sarjani Coretech, CNC-controlled Canwin CTL machines provide high repeatability and precision in every batch. The outcome is laminations with tight dimensional tolerances, minimal burrs, and uniform stacking quality, all contributing to quieter, vibration-free transformers.