Novel Transformer Core Design Using Consolidated Stacks of Electrical Steel

The conventional way of building stacked transformer cores is a tedious and time-consuming operation.This paper introduces a novel way of building transformer cores, namely the sub-cores, using consolidated stacks of electrical steel to reduce construction times without causing an increase in the core losses.Three core designs, a conventional butt-lap core, a brick core and a sub-core were built and tested.It is possible to construct 50 kVA, single-phase, transformer cores made out of consolidated stacks of electrical steel whilst significantly reducing construction times and slightly improving the power loss compared to conventional butt-lap cores.