Nanocrystalline Cut Cores

Low Power Losses for Medium Frequency Transformers

Nanocrystalline cut cores made of VITROPERM® 500 offer excellent soft magnetic characteristics with very low iron losses. They are an excellent choice for high performance applications like medium-frequency transformers (MFTs).  

 

Benefits:

  • Very low specific power losses
  • High excitation levels ≥0.8 T
  • Operating temperature ≤150 °C

Nanocrystalline cut cores are typically used for medium-frequency transformers in the following applications: 

  • Railways
  • Smart grids & renewables
  • DC fast chargers for electric vehicles

General Characteristics

Geometrical shape toroidal, oval, rectangular
Position of cut (typ.) at the longer side of the core
Number of cuts (typ.) 1 (multiple cuts upon request)
Weight of core (typ.) 50 g - 30 kg
Max. operating temperature ≤150 °C
Magnetic flux density (typ.) ≤0.9 T (unipolar)
Effective permeability (w/o air gap) > 5,000

 

Medium-frequency solid-state transformers based on new wide band gap materials are nowadays seen as the key drivers for high power applications. Aiming at different fields of applications like railway, smart power grids and DC fast charging for electric vehicles, especially the inductive components are critical for size, weight and performance of the complete system: Switching frequencies between 1 kHz and up to 50 kHz for high power levels beyond 100 kVA allow for an effective reduction in the size of all magnetic components.

Offering the lowest specific power losses in the medium-frequency range at a considerably high saturation of 1.2T, nanocrystalline materials help to drive this transformation.

New Production Process for Nanocrystalline Cut Cores and Customer Benefits

VAC has mastered the production process of nanocrystalline cut cores, overcoming the typical steep increase of the specific power losses after cutting the brittle nanocrystalline cores. These improvements of the complete production chain come along with a number of technical benefits from an application point of view: The high filling factor allows more compact designs, reducing the footprint and volume of the end application. The high temperature class allows for continuous operating temperature of up to 150 °C.

The key advantage, however, clearly has to be seen in the reduction of the specific power losses: The diagram details the specific power losses versus the peak flux density at fixed switching frequency between 1 kHz and 20 kHz. It is obvious that the nanocrystalline cut core stays operational even at very high flux densities of up to 1 T.

Nanocrystalline cut cores are typically used for medium-frequency transformers in the following applications: 

  • Railways
  • Smart grids & renewables
  • DC fast chargers for electric vehicles

General Characteristics

Geometrical shape toroidal, oval, rectangular
Position of cut (typ.) at the longer side of the core
Number of cuts (typ.) 1 (multiple cuts upon request)
Weight of core (typ.) 50 g - 30 kg
Max. operating temperature ≤150 °C
Magnetic flux density (typ.) ≤0.9 T (unipolar)
Effective permeability (w/o air gap) > 5,000

 

Medium-frequency solid-state transformers based on new wide band gap materials are nowadays seen as the key drivers for high power applications. Aiming at different fields of applications like railway, smart power grids and DC fast charging for electric vehicles, especially the inductive components are critical for size, weight and performance of the complete system: Switching frequencies between 1 kHz and up to 50 kHz for high power levels beyond 100 kVA allow for an effective reduction in the size of all magnetic components.

Offering the lowest specific power losses in the medium-frequency range at a considerably high saturation of 1.2T, nanocrystalline materials help to drive this transformation.

New Production Process for Nanocrystalline Cut Cores and Customer Benefits

VAC has mastered the production process of nanocrystalline cut cores, overcoming the typical steep increase of the specific power losses after cutting the brittle nanocrystalline cores. These improvements of the complete production chain come along with a number of technical benefits from an application point of view: The high filling factor allows more compact designs, reducing the footprint and volume of the end application. The high temperature class allows for continuous operating temperature of up to 150 °C.

The key advantage, however, clearly has to be seen in the reduction of the specific power losses: The diagram details the specific power losses versus the peak flux density at fixed switching frequency between 1 kHz and 20 kHz. It is obvious that the nanocrystalline cut core stays operational even at very high flux densities of up to 1 T.

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Customized product solutions for all industries: VAC‘s nanocrystalline cut cores are fully customized solutions. We look forward to receiving your technical requests.

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