ARTIFICIAL EYE

SEMINAR REPORT

Submitted by

SHAMEEM ARAFATH. E

(Reg.NO: 20030394)

in partial fulfilment for the award

DIPLOMA IN
ELECTRICAL AND ELECTRONICS ENGINEERING

ORPHANAGE POLYTECHNIC COLLEGE, EDAVANNA

DEPARTMENT OFELECTRICAL AN ELECTRONICS

ENGINEERING

APRIL 2022
 BONAFIDE CERTIFICATE

It is Certified that this seminar report “AMORPHOUS CORE TRANSFER”

Is the Bonafide work of SHAMEEM ARAFATH. E (Reg. NO: 2003039) who
carried out the work under guidance for the partial fulfillment of the requirement for
the award of the Diploma in Electrical and Electronics Engineering at Orphanage
Polytechnic College, Edavanna.

Mr. ASHIKALI P MR. JASEEL JASIM V

HEAD OF DEPARTMENT SEMINAR CO-ORDINATOR
Electrical & Electronics Engineering Electrical & Electronics Engineering
Orphanage Polytechnic College Orphanage Polytechnic College
Edavanna Edavanna

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 ABSTRACT

Amorphous core transfer (ACT) is a technique used for high-efficiency power

distribution in electrical transformers. It involves the use of amorphous metal,
which has unique magnetic properties that allow for reduced energy losses in the
transformer. The ACT process involves melting the amorphous metal and
transferring it onto a substrate, where it solidifies into a thin ribbon. This ribbon is
then wound into a core, which is used in the transformer. The use of amorphous
metal cores in transformers can result in significant energy savings, lower operating
temperatures, and reduced environmental impact compared to traditional
transformers.
 ACKNOWLEDGEMENT

I very much grateful to the authorities of Orphanage Polytechnic College,

Edavanna for providing the facilities needed during the seminar presentation

My deepest gratitude and thanks to our Principal Mr. Mansoor Ali PP who has
been kind enough and encouraging us always during the entire period of our
course.

I gratefully acknowledge the valuable help and advice received from

Mr. Ashikali.P Head of Department of Electrical and Electronics Engineering
whose continuous encouragement that has resulted in the completion of the
present work. His timely advice, meticulous scrutiny, scholarly advice and
friendly approach have helped us to a very great extent to accomplish this
work.

I would also like to express my profound thanks to my class tutor Miss.

Shifana.N P Lecturer in Department of Electrical and Electronics Engineering
whose thoughtful words helped us in completing my seminar successfully. Also
I would like express my sincere thanks to my seminar co-ordinator Mr. Jaseel
Jasim.V demonstrator in Department of Electrical and Electronics Engineering
whose instructions helped more to do my seminar presentation.

We thank profusely all the Teaching and non-teaching Faculty members of

Electrical and Electronics Engineering Department and my family members
for being my supporting force during my seminar presentation.

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TABLES OF CONTENTS
 LIST OF FIGURES

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 CHAPTER 1

INTRODUCTION

Amorphous core transformers, also known as amorphous metal transformers or

amorphous metal core transformers, are a type of transformer that use a magnetic
core made of amorphous metal. Amorphous metal is a type of metal that lacks a
crystalline structure and is formed by rapidly cooling molten metal. This results in a
material with unique properties, including high magnetic permeability, low core
loss, and high resistance to magnetic aging.

In amorphous core transformers, the amorphous metal is used to make the core,
which is the part of the transformer that is responsible for transferring energy
between the primary and secondary coils. Compared to traditional transformer cores
made of laminated steel, amorphous core transformers have lower losses, higher
efficiency, and a smaller physical size. They are particularly well-suited for
applications where energy efficiency is a priority, such as in power distribution
systems, renewable energy systems, and electric vehicles.

Amorphous core transformers are typically more expensive than traditional

transformers, but their improved efficiency can lead to significant cost savings over
the lifetime of the transformer. Additionally, as energy efficiency becomes an
increasingly important consideration in many industries, the demand for amorphous
core transformers is expected to grow in the coming years.
 CHAPTER 2

THE HISTORY OF AMORPHOUS CORE TRANSFER

The history of amorphous core transfer (ACT) dates back to the 1970s when
researchers first discovered the unique magnetic properties of amorphous metals.
Amorphous metals, also known as metallic glasses, are materials that lack the
ordered crystalline structure of most metals. Instead, they have a disordered atomic
structure, which gives them unique physical properties, including high magnetic
permeability, low coercivity, and low core loss.

In the early 1980s, researchers at Allied-Signal Corporation (now Honeywell

International) developed a technique for producing amorphous metal ribbons using
a rapid solidification process. This process involved rapidly cooling the molten
metal on a spinning metal drum, which resulted in the formation of a thin ribbon of
amorphous metal.

In 1983, Allied-Signal introduced the first commercial transformer using an

amorphous metal core. These transformers were significantly more efficient than
traditional transformers, with core losses that were up to 80% lower. This led to the
widespread adoption of amorphous metal cores in a range of applications, including
power transformers, distribution transformers, and inductors.

In the years since, researchers have continued to refine the process of amorphous
core transfer, developing new techniques for producing amorphous metal ribbons
and optimizing the design of transformers and other devices that use amorphous
metal cores. Today, amorphous metal cores are widely used in a range of
applications, from power generation and transmission to consumer electronics and
renewable energy systems.

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 CHAPTER 3

CMPONENTS USED IN AMORPHOUS CORE TRANSFER

3.1 AMORPHOUS CORE

Fig 3.1

An amorphous core, also known as a metallic glass core or simply an amorphous

metal core, is a type of transformer core material used in electrical power
distribution applications.

Unlike traditional transformer cores, which are made from crystalline materials such
as silicon steel, amorphous cores are made from a non-crystalline or disordered
metallic alloy. This amorphous alloy is typically composed of a mixture of metals
such as iron, nickel, cobalt, and boron, and it is rapidly solidified to create a non-
crystalline structure.

The use of amorphous cores in transformers can provide a number of benefits,

including reduced core losses and increased efficiency. This is because the non-
crystalline structure of the amorphous metal reduces magnetic hysteresis losses,
which occur when the magnetic field in the core is repeatedly reversed.

Amorphous cores are also more resistant to overheating and saturation, which can
occur when a core is subjected to a high magnetic field. This makes them ideal for
use in high-frequency applications and in transformers that need to operate at higher
temperatures.

Overall, the use of amorphous cores can result in more efficient and reliable
transformers, making them an attractive option for many power distribution
applications.

3.2 PRIMARY AND SECONDARY WINDING

Fig 3.2

In terms of primary and secondary windings, amorphous core transformers function

in the same way as traditional transformers. The primary winding is the coil of wire
that is connected to the input voltage source, while the secondary winding is the coil
of wire that is connected to the output load.

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When an AC voltage is applied to the primary winding, it creates a magnetic field
that flows through the core and induces a voltage in the secondary winding. The
amount of voltage induced in the secondary winding depends on the number of
turns in the primary and secondary windings, as well as the magnetic properties of
the core material.

In an amorphous core transformer, the amorphous metal alloy is typically wound

into a toroidal shape to form the core. The primary and secondary windings are then
wrapped around the core, with the primary winding usually being wound closer to
the core than the secondary winding. This helps to minimize energy loss and reduce
noise.

In summary, the primary and secondary windings of an amorphous core transformer

function in the same way as traditional transformers, with the only difference being
the use of an amorphous metal alloy core instead of a laminated iron core.

3.4 INSULATION

Fig 3.3

The insulation of amorphous core transformers should meet the electrical and
thermal requirements of the application. Insulation materials should have high
dielectric strength and low thermal conductivity to minimize energy losses. The
choice of insulation material will depend on the specific application and
environmental conditions.

Typically, amorphous core transformers are insulated using materials such as

Mylar, Nomex, or Kapton, which are high-performance insulating materials. These
materials have excellent dielectric properties, high mechanical strength, and high
temperature resistance.

Additionally, proper insulation design and installation is crucial to ensure that the
insulation is effective. The winding arrangement and insulation thickness should be
carefully considered to avoid voltage breakdown and ensure a safe and reliable
operation.

In summary, proper insulation is essential for amorphous core transformers to

achieve high efficiency and safety. The insulation materials and design should be
carefully selected based on the specific requirements of the application.

3.5 COOLING SYSTEM

Amorphous core transformers are designed with a core made from an amorphous
metal alloy, which has lower core losses than traditional transformer cores made
from laminated silicon steel. However, amorphous core transformers still generate
some amount of heat during operation, and a cooling system is necessary to
maintain safe operating temperatures.

The cooling system for an amorphous core transformer typically includes a cooling
medium, such as oil or water, which is circulated through the transformer’s core and
windings to transfer heat away from the transformer. The cooling medium may be
circulated by natural convection, or it may be forced through the transformer by a
pump or other means.

In addition to the cooling medium, the transformer may also be equipped with
cooling fins or other cooling devices to increase the surface area available for heat

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transfer. These cooling devices help to improve the efficiency of the cooling system
and reduce the operating temperature of the transformer.

Overall, the cooling system is an important aspect of the design of an amorphous

core transformer, as it helps to maintain safe operating temperatures and prolong the
life of the transformer.

3.6 TERMINAL BLOCKS

Terminal blocks are commonly used in electrical and electronic circuits to connect
multiple wires or cables. They are a type of electrical connector that allows for easy
and secure connections between wires. Terminal blocks are available in various
shapes, sizes, and designs, and they can be made from different materials, such as
plastic, ceramic, or metal.

In the context of amorphous core transformers, terminal blocks may be used to

connect the input and output wires of the transformer to other components in the
circuit. The terminal blocks provide a convenient and reliable way to make these
connections, while also ensuring that the wires are properly secured and protected
from damage. Overall, terminal blocks are a critical component of many electrical
and electronic circuits, including those that use amorphous core transformers
 CHAPTER 4

CONSTRUCTION

An amorphous core transfer is a type of transformer that uses amorphous metal

cores instead of traditional laminated metal cores. Amorphous metal cores are made
of a special alloy that has a disordered atomic structure, which gives them unique
magnetic properties that make them ideal for use in transformers.

Here are the steps for constructing an amorphous core transfer:

1. Design the transformer: The first step in constructing an amorphous core

transfer is to design the transformer. This involves determining the desired
specifications such as the input and output voltages, current rating, and
frequency range.
2. Choose the amorphous metal alloy: The next step is to select the amorphous
metal alloy that will be used to make the core. Some common alloys used for
amorphous cores include FeSiB, FeCoSiB, and FeNbCuSiB. The alloy can
be purchased from suppliers or manufactured in-house using a specialized
process.
3. Fabricate the core: The amorphous metal alloy is usually produced in the
form of a ribbon or wire. The ribbon or wire is wound into a core shape using
specialized equipment. The core can be in the form of a toroid, E-core, or
other shapes depending on the design of the transformer.
4. Wind the primary and secondary coils: The next step is to wind the primary
and secondary coils around the amorphous metal core. The coils are usually
made of copper wire and are wound in a specific pattern to achieve the
desired voltage and current rating.

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5. Insulate the coils: After the coils are wound, they are typically insulated to
prevent electrical shorting. This is usually done using insulating tape or
varnish.
6. Mount the transformer: The final step is to mount the transformer in a
suitable enclosure. The enclosure is usually made of a non-conductive
material such as plastic or metal and is designed to protect the transformer
from damage and prevent electrical shock.
 CHAPTER 5

WORKING

Amorphous core transformers are a type of electrical transformer that use a core
made of a material called amorphous metal. Amorphous metal is a type of alloy that
has a disordered atomic structure, which gives it unique magnetic properties.

In a typical transformer, the core is made of laminated steel sheets that are stacked
together to form a solid core. The laminations are insulated from each other to
reduce eddy current losses. However, in an amorphous core transformer, the core is
made of a continuous ribbon of amorphous metal that is wound into a coil shape.

The amorphous metal ribbon is very thin, typically between 0.025 and 0.050 mm in
thickness. The ribbon is wound into a coil shape and then encapsulated in a
protective material to form the core. The winding process is typically done using a
machine that controls the tension and alignment of the ribbon to ensure a consistent
winding.

The unique magnetic properties of amorphous metal result in very low core losses,
which makes amorphous core transformers much more energy-efficient than
traditional transformers. The low losses are due to the disordered atomic structure of
the amorphous metal, which reduces the formation of magnetic domains that can
cause energy loss.

Amorphous core transformers are used in a variety of applications, including power

distribution, industrial equipment, and renewable energy systems. They are
particularly well-suited for applications where energy efficiency is a priority, as
they can reduce energy consumption and lower operating costs.

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 CHAPTER 6

COMPARISON BETWEEN AMORPHOUS CORE TRANSFER

AND CRGO CORE TRANSFER

PROPERTIES CRGO CORE AMORPUSH CORE

TRANSFORMER TRANSFORMER
Magnetic properties High Determine Low
Efficiency Low High

Cost Low High

Size More Less

Noise More Less

 CHAPTER 7

PERFORMANCE EVALUATION OF AMORPHOUS CORE

TRANSFER

Amorphous core transformers (ACTs) have gained popularity due to their improved
energy efficiency, reduced losses, and increased reliability compared to traditional
transformers. Performance evaluation of an ACT involves measuring its key
parameters, such as power efficiency, losses, and temperature rise, to assess its
overall performance and determine its suitability for a given application.

Here are some common methods for performance evaluation of amorphous core
transformers:

1. Power Efficiency Testing

2. Losses Measurement
3. Temperature Rise Testing
4. Noise Measurement

7.1 Power Efficiency Testing

To test the power efficiency of an amorphous core transformer, you can perform
a power efficiency test. The power efficiency test measures the ratio of output
power to input power, and is typically performed by applying a known amount
of power to the transformer and measuring the output power.
Here are the steps you can follow to perform a power efficiency test on an
amorphous core transformer
1. the input voltage and current ratings of the transformer, and the output
voltage and current ratings of the load.

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 2. Connect the transformer to a power source with the appropriate input
voltage and current ratings, and connect the load to the output of the
transformer.
3. Measure the input voltage and current using a voltmeter and an ammeter,
respectively.
4. Measure the output voltage and current using a voltmeter and an
ammeter, respectively.
5. Calculate the input power by multiplying the measured voltage and
current values.
6. Calculate the output power by multiplying the measured output voltage
and current values.
7. Calculate the power efficiency by dividing the output power by the input
power and multiplying by 100 to get a percentage.
8. Repeat the test several times to ensure accurate results and calculate the
average power efficiency.

7.2 Losses Measurement

There are two types of losses in an amorphous core transformer: core losses and
winding losses.

i. Core losses: Core losses are the losses that occur in the magnetic core due
to hysteresis and eddy currents. Hysteresis losses occur because the
magnetic field in the core causes the atoms to realign, which results in
energy being dissipated as heat. Eddy current losses occur because the
changing magnetic field induces currents in the core, which also results in
energy being dissipated as heat. Core losses are measured in watts and are
also known as iron losses.
 ii. Winding losses: Winding losses are the losses that occur in the
transformer windings due to the resistance of the wire. The current
flowing through the wire generates heat, which results in energy being
dissipated as heat. Winding losses are also measured in watts and are
proportional to the square of the current flowing through the winding.

To measure the losses in an amorphous core transformer, you can conduct a

no-load and load test. The no-load test measures the core losses, and the load
test measures both the core and winding losses.

During the no-load test, the transformer is connected to a voltage source but
no load is connected to the secondary winding. The power input to the
transformer is equal to the core losses, which can be measured using a
wattmeter.

During the load test, the transformer is connected to a load on the secondary
winding, and the input power and output power are measured using
wattmeters. The difference between the input power and the output power is
the sum of the core and winding losses.

7.3Temperature Rise Testing

Amorphous core transformers are known for their high energy efficiency and
low core losses compared to traditional transformers. However, they still need to
undergo temperature rise testing to ensure their safe and reliable operation.
Temperature rise testing involves measuring the temperature of various parts of
the transformer while it is operating under full load conditions. This testing is
necessary to ensure that the transformer can handle the expected operating
temperatures without experiencing any performance issues or damage.
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To perform temperature rise testing on an amorphous core transformer, you
should follow these steps:
i. Measure the initial temperature: Before the test, measure the initial
temperature of the transformer’s various components, such as the
windings, core, and oil.
ii. Apply full load: Apply full load to the transformer for a specific duration.
The duration of the test will depend on the transformer’s size and
expected operating conditions. The full load should be applied gradually
over a period of time to avoid sudden stress on the transformer.
iii. Measure temperatures: Measure the temperature of the various
components of the transformer at regular intervals during the test. Use
thermocouples or infrared cameras to get accurate temperature readings.
iv. Compare readings: Compare the temperature readings with the
transformer’s temperature rise limits specified in the manufacturer’s
documentation. If the measured temperatures are within the limits, the
transformer is considered safe to operate.
v. Interpret results: Interpret the test results and identify any potential issues
that need to be addressed. If the temperature readings exceed the limits,
then the transformer needs further investigation to determine the cause of
the issue.

7.4 Noise Measurement

When measuring the noise of an amorphous core transformer, it is important to

consider the following steps:
i. Determine the measurement standard: The measurement standard for
transformer noise depends on the application and specific requirements.
Generally, the most common standard used is the IEC 60076-10, which
 provides the procedure for measuring the noise level of power
transformers
ii. Prepare the testing environment: The testing environment should be
quiet, and any sources of external noise should be minimized. The
transformer should also be placed on a stable surface to prevent any
vibrations or movement that could affect the noise level.
iii. Connect the equipment: Connect a calibrated sound level meter to the
transformer, and ensure that the meter is set to the appropriate
measurement range.
iv. Apply a test voltage: Apply a test voltage to the transformer to generate a
magnetic field. The voltage should be appropriate for the transformer’s
rated power.
v. Record the noise level: Once the magnetic field is applied, record the
noise level from the sound level meter. It is recommended to take several
measurements at different locations around the transformer to ensure an
accurate representation of the noise level.
vi. Analyze the results: Analyze the recorded noise levels and compare them
with the acceptable noise level limits for the transformer type and
application. If the noise level is too high, it may be necessary to
investigate the cause of the excess noise and take corrective measures.

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 CHAPTER 8

ADVANTAGES AND DISADVANTAGES

ADVANTAGES

1. Higher energy efficiency: Amorphous core transformers have lower

core losses compared to traditional transformers due to their unique
atomic structure, which results in a lower magnetic hysteresis loss.
This makes them more energy-efficient, which can save significant
amounts of electricity and reduce operating costs.
2. Reduced noise and vibration: The amorphous metal used in the core
of these transformers has a homogeneous and isotropic structure,
which reduces the magnetostriction effect that can lead to noise and
vibration. As a result, amorphous core transformers are generally
quieter and more stable than traditional transformers.
3. Lower operating temperature: The lower core losses of amorphous
core transformers also mean that they operate at a lower temperature
compared to traditional transformers. This reduces the risk of
overheating, extends the life of the transformer, and reduces the need
for cooling systems
4. Higher overload capacity: Amorphous core transformers have a higher
overload capacity compared to traditional transformers, which means
they can handle higher loads without the risk of overheating or
damage.
5. Lower environmental impact: Amorphous core transformers are more
environmentally friendly than traditional transformers because they
use less energy and produce less greenhouse gas emissions.
 Additionally, amorphous metal can be recycled, making it a
sustainable material choice.

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DISADVANTAGES

1. Higher Cost: Amorphous core transformers can be more expensive

than traditional transformers due to the cost of the amorphous metal
used in their construction.
2. Lower Saturation Flux Density: Amorphous core materials typically
have a lower saturation flux density than traditional transformer core
materials, which can limit the maximum magnetic flux density that
the transformer can handle.
3. Lower Efficiency at Low Loads: Amorphous core transformers are
less efficient at low loads than traditional transformers, which can
result in energy losses.
4. Fragility: Amorphous core materials are more brittle and fragile than
traditional transformer core materials, which can make handling and
installation more challenging.
5. Limited Availability: The availability of amorphous metal can be
limited, which can make it difficult to obtain the materials necessary
to manufacture amorphous core transformers.
 CHAPTER 9
APPLICATIONS OF AMORPHOUS CORE
TRANSFER

1. Power Distribution: Amorphous core transformers are used in power distribution

systems to step down the voltage of high voltage power transmission lines to
lower voltage levels that can be used by households and businesses. They can
reduce energy loss during transmission, and they are more efficient than
traditional transformers because they have lower core losses.
2. Renewable Energy Systems: Amorphous core transformers are also used in
renewable energy systems, such as wind turbines and solar panels. They can be
used to step up the voltage of the generated electricity to a level that can be
transmitted over long distances with less energy loss.
3. Industrial Applications: Amorphous core transformers are used in various
industrial applications, such as welding equipment, induction heating, and arc
furnaces. They are also used in industrial motors and generators to reduce
energy loss and improve efficiency.
4. Railway Systems: Amorphous core transformers are used in railway systems to
step down the high voltage power from the overhead wires to a level that can be
used by the trains. They are also used in railway signaling systems and lighting
systems
5. Energy Storage Systems: Amorphous core transformers are used in energy
storage systems, such as battery energy storage systems and flywheel energy
storage systems. They can be used to step up the voltage of the stored energy to
a level that can be used by the grid or other applications.

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 CONCLUSION

Amorphous core transformers are an innovative and energy-efficient alternative to

traditional transformers. The use of amorphous metal alloys in the core of these
transformers reduces core losses, resulting in improved energy efficiency and lower
operating costs.

Compared to traditional transformers, amorphous core transformers offer a number

of benefits, including reduced energy consumption, lower operating temperatures,
increased reliability, and reduced environmental impact. They are also smaller and
lighter than traditional transformers, making them ideal for use in urban areas or
where space is limited.

Amorphous core transformers are widely used in a variety of applications, including

power distribution, renewable energy, and industrial settings. Their energy
efficiency and environmental benefits make them an attractive option for businesses
and organizations looking to reduce their carbon footprint and energy costs.

In conclusion, amorphous core transformers offer significant advantages over

traditional transformers in terms of energy efficiency, reliability, and environmental
impact, and are a promising technology for the future of energy distribution and
management.
 REFERENCES

1. https://chat.openai.com/chat
2. https://www.academia.edu/66847043/
Amorphous_Core_Distribution_Transformers_Challenges_Opportunity_and
_Loss_Capitalization_for_Power_Applications_in_India
3. https://en.wikipedia.org/wiki/Amorphous_metal_transformer

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