• AC Voltmeter
• Aluminium Foil Transformer
• Amp-Hr Meter
• Hot Runner
• Stablilizer
• Digital Temperature Controller

Aluminium Foil Transformer

Aluminium Foil Transformer

INTRODUCTION

We, M. R. Electricals, are manufacturersof Power Conditioning equipmentand Instrumentation and Control equipment for energy management. Our products are marketed under the brand NIYANTAN. In the year 2000, we have gone for a Aluminium foil winding machine and know how for Aluminium foil wound transformers from the market leader with a market share of over 30 % in southern and western India, M/S Alacrity Electronics Ltd. They market market their products under the brand ‘KRYKARD’.

As our power conditioning range of products had high copper content, the possibility of reducing our dependance on copper due to its relative high cost price instability was considered. This resulted in our using Aluminium foil wound transformers in place of copper wire wound one.

The Aluminium foil wound transformers developed by Alacrity Electronics Ltd. Have been successfully used in Stabilizers and Isolation Transformers manufactured by them and about 60,000 of these are working on the field since 1992.

TECHNICAL ADVANTAGES

1. Compact size and reduced weight
   The foil design facilitates higher accommodation of the window area and so, there is no increase in the size of transformers. In fact, in some cases transformer sizes are reduced because of the foil design.
   As coils wound with Aluminium foil would weight as much as 60 % less than coils wound with copper wire, Aluminium foil transformers will be compact and lighter.

2. Increased thermal stability and higher short-term over load capacity
   The layer type winding in Aluminium foil provides a larger surface area for cooling. Since the heat gets efficiently transferred from the inner layers to the outer layers, the winding achieves thermal stability in a very short time.
   
   This, plus the fact that the specific heat of aluminium is greater than copper, helps in preventing burn-outs due to hot spots and makes the transformer withstand higher short-term over loads.

3. Higher surge withstanding capability
   The inter layer capacitance of Aluminium foil winding is greater than the winding made out of wire and so, the surge developed in a Aluminium foil transformer is equally distributed among all turns in less time than wire wound transformers, giving them higher surge withstanding capability.

4. Enhanced ability to withstand short circuit currents
   Improved balance between magnetic fluxes of primary and secondary windings enhances the capability of Aluminium foil transformers to withstand short circuits, rendering them superior to wire wound or strip wound transformers.

5. Reduced impact of harmonics snd high frequency on the design of transformers
   The ratio surface area to conducting area being higher in foils than wire, heat generated by skin effect is reduced. This in turn reduces the need to de-rate conductors, used in the application of handling currents of higher frequency or containing a high percentage of higher order harmonics.

6. Greater insulation reliability
   In foil wound transformer, the voltage gradient between layers is the voltage gradient per turn. This reduces the strain on the inner layer insulation and increases reliability.

COMMERCIAL ADVANTAGES

1. Reduced material costs
   Weight for weight, aluminium is twice as conductive as copper. Therefore, by using only 2.5 kg. Of aluminium a conductor can acquire a current carrying capacity, same as that provided by 5 kg of copper. And the cost of aluminium foil is much less than super enameled copper wire.
   
   Therefore, depending on the nature of the transformer, substitution of copper by aluminium will result in an overall saving on material cost from 20 to 40 percent.

2. Stable material costs
   Copper is imported and subject to international price and currency fluctuations. Aluminium availability is ten times more than copper in ore form.

3. Competitive price
   You can price the Aluminium foil wound transformers lower than copper wound transformers and all equipment incorporating them will automatically cost less.

4. Higher productivity of transformers handling larger currents
   For conductors with larger cross section, the inherent flexibility of foils will enable easy winding, which in turn will enhance productivity in manufacture.

5. Saving in fright and packaging
   Aluminium is much lighter than copper. Therefore, Aluminium foil transformers will be 15 % lighter than the copper wound transformers. You can thus save on packaging and freight charges.