“CORE ASSEMBLY”

A simple two-winding transformer construction consists of every winding being wound on a

separate soft iron limb or core which provides the required magnetic circuit.
This magnetic circuit, know more commonly because the “transformer core” is meant to
supply a path for the magnetic flux to flow around, which is important for induction of the
voltage between the 2 windings.

However, this sort of transformer construction where the 2 windings are wound on separate

limbs isn't very efficient since the first and secondary windings are well separated from one
another. This leads to an occasional magnetic coupling between the 2 windings similarly as
large amounts of magnetic flux leakage from the transformer itself. But also as this “O” shapes
construction, there are differing kinds of “transformer construction” and styles available which
are wont to overcome these inefficiencies producing a smaller more compact transformer.

Transformer Core Types

These lamination stampings when connected together form the required core shape. For
example, two “E” stampings plus two end closing “I” stampings to give an E-I core forming one
element of a standard shell-type transformer core. These individual laminations are tightly
butted together during its construction to reduce the reluctance of the air gap at the joints
producing a highly saturated magnetic flux density.
Transformer core laminations are usually stacked alternately to each other to produce an
overlapping joint with more lamination pairs being added to make up the correct core
thickness. This alternate stacking of the laminations also gives the transformer the advantage of
reduced flux leakage and iron losses. E-I core laminated transformer construction is mostly used
in isolation transformer’s, step-up and step-down transformer’s as well as the auto transformer
[1].

PROCEDURE:
1. The basic raw-material is COLD ROLLED GRAIN ORIENTED (CRGO) Silicon Steel.
2. It is within the style of thin sheets & move size as per design.
3. Generally three different shapes of core laminations are utilized in one assembly.
4. Notching is performed to extend the magnetic path.
5. The laminations are put through annealing process.
6. These laminations are assembled in such a way that there's no air gap between the joints of two
consecutive sheets.
7. The entire assembly is completed on a frame commonly referred to as core channel. These
frames being employed as a clamping support of the core assembly [2].

Reference:
[1] https://www.electronics-tutorials.ws/transformer/transformer-construction.html

[2] http://www.oswaltransformers.com/manufacturing-process.php