As a key player in enhancing transformer energy efficiency, CHH Power places great emphasis on understanding and minimizing the two primary sources of transformer losses—iron loss and copper loss. These losses not only reduce the transformer’s power conversion efficiency but also lead to core heating and temperature rise, directly affecting operational stability and service life. Below is a detailed breakdown of how these losses occur and CHH Power’s targeted optimization strategies.
1. Eddy Currents and Iron Loss: Core-Related Energy Dissipation
When the primary winding of a transformer is energized, the alternating current in the coil creates a magnetic flux that circulates within the iron core. Since the iron core is a conductive material, this changing magnetic flux induces an electromotive force (EMF) in the plane perpendicular to the magnetic field lines.
- Eddy Current Formation: This induced EMF generates a closed-loop current on the iron core’s cross-section. The current flows in a swirling pattern, resembling a vortex—hence the name “eddy current.”
- Iron Loss Generation: Eddy currents encounter resistance as they flow through the iron core, converting electrical energy into heat. This heat dissipation is defined as “iron loss” (or core loss), which remains relatively constant during transformer operation, independent of the load rate.
To mitigate iron loss, CHH Power uses laminated high-silicon silicon steel sheets for core manufacturing. Each sheet is coated with an insulating layer to break up the eddy current loops, significantly reducing current intensity and cutting iron loss by up to 40% compared to traditional solid iron cores.
2. Copper Loss: Winding-Related Power Consumption
Transformers require large quantities of copper wire (or high-conductivity alloys) to wind their primary and secondary windings. While copper is an excellent conductor, it still has inherent electrical resistance.
- Copper Loss Mechanism: When current flows through the copper windings, the resistance converts a portion of the electrical energy into heat. This heat dissipation is known as “copper loss,” which varies with the square of the load current—meaning it increases significantly as the transformer operates under higher loads.
CHH Power addresses copper loss by:
- Selecting high-purity oxygen-free copper wires with lower resistivity, reducing inherent resistance by 15% compared to standard copper.
- Optimizing winding design using computer-aided simulation to minimize wire length and improve current distribution, further lowering energy loss under full-load conditions.
3. Impact of Losses: Temperature Rise and Efficiency Reduction
Both iron loss and copper loss contribute directly to the transformer’s temperature rise, which is a critical factor in determining its operational lifespan. Excessive heat can accelerate insulation aging and increase the risk of mechanical failure.
- Efficiency Gap: Due to these unavoidable losses, the transformer’s output power is always less than its input power. The efficiency (output power/input power × 100%) is a key performance indicator—CHH Power’s advanced transformers achieve efficiencies exceeding 99% for large power units and 98.5% for distribution transformers, thanks to the loss-reduction measures outlined above.
By focusing on core material innovation and winding design optimization, CHH Power effectively controls iron and copper losses, ensuring its transformers deliver high efficiency, low temperature rise, and long-term reliable operation for grid applications.