Unicore

machine

DUO & DG
core

DUO
assembly

Other
cores

Savings

Transformers

Innovation in
Transformer Cores
and Manufacturing

Basic
info

AEM Unicore

References

October 2008

Basic information
History of the Unicore technology
AEM Cores Pty Ltd began operations in 1958 as a manufacturer of arc
welders. Shortly after it began production of cut cores (C cores). From
the 1970s AEM was the leader in specialist wound core manufacturing
in Australia, producing single and three phase cut cores, toroidal cores in
GOSS and Mumetal (NiFe) materials, and Distibuted Gap Cores. Today,
AEM is the only specialist wound core manufacturer in South East Asia.
Because the market being served is small and very demanding of special
designs, AEM has for many years developed its own specialist machinery. During the late 1980s and early 1990s the high cost of manufacturing the labour intensive cut cores forced
AEM to look for methods of increased automation. The philosophy of AEM, driven by the founder and owner, Bill
Jenkinson, has always been to strive for greater and greater transformer efficiency through innovative core design.
In the mid-1990s engineers at AEM produced prototype machinery to produce Unicores. The Unicore Technology was successfully used for some time by AEM and its customers before large core manufactures visiting from
overseas saw it. They immediately wanted to buy the Unicore machine so that they could provide the advantages
of Unicore products to their markets.
More than 120 machines have been manufactured and Unicores are now being produced* or used in the following countries:
Australia*
Benelux
Brasil*
Canada*
Chile*
Colombia*

Czech Republic*
France
India*
Italy*
Korea*
Macedonia*

Malaysia*
Mexico*
New Zealand*
Norway
Poland
Russia*

South Africa*
Spain*
Turkey*
United Kingdom
USA*
Venezuela*

The latest development is the DUO core. It is a low loss Unicore designed for easy assembly. This core is expected
to slowly replace the use of large E&I, strip laminations and C cores.
We feel that ever tightening enviromental standards and efficiency requirements will drive the market towards
high efficient Unicore poducts further in the future.

Advantages
The Unicore technology is very flexible, highly accurate, repeatable and reliable. Unlike production of toroidal and
cut cores, it does not require any fixed tooling, such
as various jigs and mandrils. Unicore laminations are
fully formed when leaving the machine.

Basic
info

For General Purpose Transformers, Unicores have

lower losses than cut cores or E&I and 90 Cut Laminations. Core assembly is very fast.
For Distribution Transformers, Unicore technology provides a highly flexible, accurate and reliable
production system with all inherent advantages of
wound core technology.
Detail of DUO3

References

Unicores

Unicores can be used for Distribution Transformers and

General Purpose Transformers from less than 1000 VA
to approx. 1500 kVA. According to latest knowledge a
10.000 kVA transformer has already been produced using our cores.
Adjustable assembly plate

Materials for Unicores

Unicores can be produced from any grade of Grain Oriented Silicon Steel (GOSS) with thickness from 0.2 to 0.35
and strip width from 20 to 300 mm. Two strips can be run simutaneously when using less than 140 mm strip.

Savings

Transformers

Similarly as toroidal or cut cores, Unicores belong to the

family of wound magnetic cores. Historically there are
more than ten different types of Unicores. Some of them
are not used any more as they were replaced by better
types.

It has been tested that some finer grades of GOSS can be also used for Unicores. For details please contact us.

Other
cores

Unicore geometry and sizes

Unicores can weigh up to 1500 kg. A Unicore is defined by the following parameters:

DUO
assembly

Window Width (WW)

Build-up (BU)
Corner Angle

DUO & DG
core

Unicore faces can be straight butt, DUOcore, Distributed Gap or Uncut. Unicores
can be produced with 30, 45 or 90
corners, depending on application. All
these values can be easily specified and
programmed.

Unicore
machine

New Unicore types are continually

developed.

Basic
info

Window Length (WL)

Strip Width (SW)
Strip Thickness (ST)
Tightness Factor (TF)

The Unicore machine

Advantages
The Unicore machine is fully programmable computer
controlled machinery. Therefore, it represents a very
flexible production technology. Just by selecting a core
type and entering core dimensions in the core definition file, one can easily produce a single core or a big
volume of cores. Just-in-time production results in low
level of inventory. No tooling is needed.
AEM Australia

Power requirements
3 phase and neutral, 415 V AC, 50/60 Hz electric
supply
6 kPa compressed air to drive the folder bar and lift
the feed roller
SAE 32 hydraulic oil to drive the guillotine

Unicore
machine

DUO core definition file

Detail of machine operation

Electric and air supply, PC connection

References

Our European installations

Transformers

More than 10 Unicore machines are operating in

Europe now.

Other
cores

Savings

ALCE Elektrik, Turkey

Zucchiatti Elettromeccanica, Italy

DUO & DG
core

DUO
assembly

VP Technotron, Czech Republic

Makitel, Macedonia

Elesa Transformadores, Spain

INTEPS, Russia

Basic
info

Unicore
machine

Vakar, Czech Republic

DUO core
Application
DUO core is the newest type of Unicore. It is a low
loss, price competitive core with very easy assembly. It
is used for core-type, single-leg and shell-type, single
and 3-phase General Purpose Transformers. Annealed
DUO cores with one lamination per overlap may be
used for Distribution Transformers.
After assembly into windings TIG welding of the last
lamination and wedging is recommended.

DUO3 core

DUO core types

To reduce assembly time, the number of laminations per overlap may be increased from 1 up to 3. Increasing
from 1 to 2 results in a 45 % decrease in assembly time, and 2 to 3 results in a further 25 % decrease. Note that
losses and magnetizing VA will increase.

DUO sizes
Dimension
Window Length (WL)
Window Width (WW)
Strip Width (SW)
Build Up (BU)

Minimum (mm)
80
40
20 (with two strips)
Material Thickness

Maximum (mm)
Unlimited*
Unlimited*
300 (with one strip)
Unlimited*

* Not limited by the Unicore machine. Limited only by practical transformer manufacturing considerations.

Material
Any grade of GOSS, thickness 0.2 to 0.35 mm.

Optional annealing

DUO & DG
core

Annealing reduces losses by 10 to 30 %, depending on the core size.

No banding
Simple TIG weld of final lamination only.

DUO1 male half

3-ph DUO3 with corner holes

References

Distributed Gap cores

Application

Transformers

DG Unicores represent a family of cores with a single cut per lamination. They are used for single-leg and shelltype, single and 3-phase Distribution Transformers.
Unlike traditional technology of producing DG cores, no tooling is needed for production of DG Unicores.

DG Unicore types

Savings

There are several different types of DG Unicores, namely a core with straight cut face, Diverging face (cascade
of cut faces fans out) and End-Overlap (spirally wound laminations) face. The position and specification of the
DG face can be easily programmed.

DG Unicore size

Minimum (mm)
60
40
20 (with two strips)
Material Thickness

Maximum (mm)
Unlimited*
Unlimited*
300 (with one strip)
Unlimited*

Other
cores

Dimension
Window Length (WL)
Window Width (WW)
Strip Width (SW)
Build Up (BU)

Not limited by the Unicore machine. Limited only by practical transformer manufacturing considerations.

Material

End-Overlap type of DG core

Optional annealing

40 kg single-phase DG core

3-ph DG core

Basic
info

Unicore
machine

DUO & DG
core

Annealing reduces losses by 10 to 30 % depending on the core size and is almost always desirable to achieve the
highest efficiency.

DUO
assembly

Any grade of GOSS, thickness 0.2 to 0.35 mm.

Single Phase DUO Core Assembly

Procedure
1. Insert the first full size inner lamination into the coils. 2. Insert the smallest male packet. 3. Insert the helper
strips. 4. Insert the corresponding female packet and then remove the strips. 5. Now repeat the steps 2 to 4 until
all packets including the last female half with the outer welding lamination have been inserted. 6. After welding
the outer lamination an insulation material may be used to lightly wedge the remaining space between the core
and the coil.

1
4

3
6

Example of a single phase DUO3 core assembly

DUO
assembly

Core size: WL 210, WW 60, SW 70, BU 60 mm

Core weight: 21 kg
Transformer power: 7.5 kVA
Core production time: 18 min Core assembly time: max 4 min

The disassembled core

Female half of the core

Partly assembled core

without bobbins

DUO3 detail

Male half of the core

Assembly plates

Taking a male packet

Taking a female packet

References

Three Phase DUO Core Assembly

Assembly of a three phase DUO core is very similar to the single phase DUO assembly. Start with assembly of
the first inner core into the coils. After the second inner core is assembled insert an insulation material to wedge
the inner cores apart so that the first outer male packet fits accurately. Last lamination of the inner cores may be
welded. Now insert the outer core.

Example of a Cast Resin Transformer

Transformer power: 50 kVA
Core assembly time: approx. 50 min

Inserting first lamination

Inserting female packet

Strapping the core

Wedging the inner cores

Start of outer core assembly

An assembly table

Source: EVPU, Slovakia

Basic
info

Unicore
machine

DUO & DG
core

DUO
assembly

First inner core assembled

Other
cores

Savings

Core weight: 164 kg

Core production time: 41 min

Transformers

Procedure

Example of a 50 kVA oil distribution transformer

DUO
assembly

Core size (DUO3): WL 210, WW 105, SW 120, BU 84 mm

Core weight: 110 kg
Core production time: 38 min Core assembly time: approx. 40 min

Source: Cotrafo, Italy

10

References

Cruciform Unicores
25 kVA dry distribution transformer with DDG1 core

DUO
assembly

Other
cores

Savings

Transformers

Core size (DDG): WL 280, WW 128, SW 60/90/120, BU 116 mm

Core weight: 152 kg
Core production time: approx. 70 min
Core assembly time: approx. 60 min

100 kVA distribution transformer with DUO2 core

11

Basic
info

Unicore
machine

DUO & DG
core

Core size: WL 345, WW 120, SW 55/75/105/120/135/145, BUP 138

Core weight: 284 kg
Core assembly time: approx. 60 minutes

Other types of Unicores

Step Butt core
This type of Unicore is used for a shell type General
Purpose Transformers only, up to approx. 1 kVA. Losses
are much higher than DUO or DG cores but less than or
comparable to a C core.

Other
cores

Replacement of laminations, 1600 VA

Butt-2 and Butt-3 cores

These cores have a gap of programmable size in
2 (single phase) or 3 (3-phase) legs. They are used
in chokes and reactors.

Butt-2 core from eight different strips

12

References
Gapped core

Transformers

It is a core with one gap of programmable size in one leg only.

Other
cores

WL

BU

Savings

WW

Demagnetizing ball bearings

Uncut core

DUO
assembly

It is a core with no cuts. The Unicore machine

is only feeding and folding steel.

DUO & DG
core

Uncut cores are used for Current and Voltage Transformers. They are always annealed
to achieve the lowest loss and magnetizing
current.

Uncut core for Petersen coil

Straight laminations

13

Basic
info

Unicore
machine

The Unicore machine can be programmed

to produce rectangular 90 cut laminations
which can be used for the manufacture
of chokes and transformers.

Savings with Unicore

Unicore Transformer
Core: Unicore DUO2 without annealing
A Window: 155 60, Strip width: 90, Buildup: 50, Core weight: 20 kg
B Window: 122 50, Strip width: 70, Buildup: 40, Core weight: 16,5 kg

Savings

Technical parameters:
A Induction: 1.4 T, Current density: 3.3 A/mm, No-load loss: 70 W
B Induction: 1.3 T, Current density: 3.0 A/mm
Dimensions:
A Width 210 Depth 155 Height 270
B Width 260 Depth 160 Height 210
Total weight:
A 31 kg
B 26 kg

A Single Phase Transformer 5000 VA

Classical Laminated Transformer

Dimensions:
A Width 240 Depth 153 Height 310
B Width 264 Depth 132 Height 228
Total Weight:
A 39 kg
B 31 kg

14

B Three Phase Transformer 3000 VA

Manual Magnetic

References

Unicore production times

As a guide a MS Excel spreadsheet is offered. By entering dimensions, production time and weight of single and
3-phase DUO and DG cores are calculated. Loading two strips less than 140 mm wide doubles capacity of the
machine.

Transformers

Unicore Production Times

Distributed Gap (DGap, DDGap, EOLap) with 45deg corner

30deg corner
Three Phase Cores
DUO E core with 45 deg corner
Distributed Gap (Ecore and Elap) with 45deg corner
30deg corner

21:43
27:54
min : sec
35:18

43
44
Core Mass (Kg)
69

119
95
Output (Kg/hr)
117

35:05
42:08

69
70

118
100

Savings

Enter Core Dimensions

WL
240
mm
WW
80
mm
SW
80
mm Strip Width is less than 130 mm, load two
BUP
80
mm strips and double production
ST
0,30
mm
Note: The calculated cycle time is for one strip, loading two strips will halve the unit time and double production.
Single Phase Cores
min : sec
Core Mass (Kg)
Output (Kg/hr)
DUO C core with 45deg corner
24:03
43
107

Other
cores

Disclaimer: This spreadsheet is offered as a guide only, its accuracy cannot be guaranteed. Data is derived by graphical interpolation of empirical tests on actual cores made on
a standard UCM2500 machine at AEM Cores Pty Ltd. Tightness Factor is assumed to be zero (default), increasing the TF will increase the core mass slightly. Dec03

Annealing Unicores
Unicores are fully formed by the machine. It means they do not have to be annealed if higher losses can be accepted. Depending on application, core size etc. one can decide that annealing is not necessary. With increasing
size of a core the difference in losses between unannealled and annealed core is getting smaller.
DUO Core - Loss (W/kg) v Flux density (T)

DUO
assembly

Two different DUO cores - Loss (W/kg) v Flux density (T)

2.2

1.6

2.0

1.4

Core Type 1 Phase

Window Length = 229mm
Window Width = 89mm
Strip Width
= 210mm
= 60mm
Core Build
= 77.7kg
Mass
Mean Path
= 0.84m

1.2

Loss (W/kg)

1.6

Loss (W/kg)

1.4

Core Type 1 Phase

Window length = 119mm
Window Width = 39mm
Strip Width
= 70mm
= 39.5mm
Core Build
Mass
= 9.1kg
Mean path
= 0.45m

1.8

1.2
1.0

1.0

Core Type 1 Phase

Window length = 119mm
Window Width = 39mm
Strip Width
= 70mm
= 39.5mm
Core Build
Mass
= 9.1kg
Mean path
= 0.45m

0.8

0.6

0.8
0.6

0.4

0.4
0.2

1.6

1.5

1.4

1.3

1.2

1.1

0.9

0.8

0.7

0.6

0.5

Flux density (Tesla)

0.0
1.7

1.6

1.5

1.4

1.3

1.2

1.1

0.9

0.8

0.7

0.6

Flux density (Tesla)

Part: 119397039.5 Duo1 1 lamination/overlap not annealed, Material=30rgh110

Part: 119397039.5 Duo2 2lamination/overlap not annealed, Material=30rgh110

Part: 119397039.5 Duo1 1 lamination/overlap not annealed, Material=30rgh110

Part: 119397039.5 Duo1 1 lamination/overlap ANNEALED, Material=30rgh110

Part: 119397039.5 Duo3 3 lamination/overlap not annealed, Material=30rgh110

Part: 119397039.5 Duo1 1 lamination/overlap ANNEALED, Material=30rgh110

Part: 2298921060 Duo1 1 lamination/overlap not annealed, Material=30rgh110

Part: 2298921060 Duo1 1 lamination/overlap ANNEALED, Material=30rgh110

Test Rig for testing Single & Three Phase Unicores

Unicore
machine

The manual magnetic test rig includes a variac connected

to a power meter with either a single phase or three
phase test leads around the test core.

0.5

Test results can be entered into

the spreadsheet producing
a graph showing interpolated
core performance vs flux density for both Power Loss (Watts)
and Magnetising Force (A/m).

15

Basic
info

0.0
1.7

DUO & DG
core

0.2

Transformers

Examples of Unicore transformers

Single-leg transformer

Core type transformer

Petersen coil with DG cores

Shell type transformer with DUO cores, Russia

230 kVA dry type transformer, Slovakia

100 kVA transformer, Italy

Shell-type DUO core transformer, Italy

16

References
Transformers
Savings

4-core 5-limb 3-ph transformer, Australia

DUO
assembly

Other
cores

3-phase choke, Italy

Unicore
machine

DUO & DG
core

Examples of instrument transformers

10 MVA transformer, South Africa

17

Basic
info

Example of frame

Transformers
10 kVA transformer, Poland

Three phase 100 kVA transformer, Poland

6.3 kVA transformer, Russia

75 kVA oil distribution transformer, Macedonia

Marine transformer, Norway

100 kVA transformer, Czech Republic

40 kVA transformer with NOSS core, Turkey

18

References
Transformers
Savings

2 kVA transformer with Stepbutt core

Australia & New Zealand

ABB Australia, Darra, Australia
AEM Cores Pty, Ltd, Gillman, Australia
ETEL Distribution Transformers, Auckland, New Zealand
Thycon, Coburg, Australia
Tyree Transformers, Mittagong, Australia
Asia
ETAH SDN. BHD., Kuala Lumpur, Malaysia
Jupiter Electricals, Vadodara, India
Han Chang Trans Co, Busan, Korea
Kotsons, Agra, India
Mangal Electrical Industries, Jaipur, India
Manu Power Equipments Pvt, Ltd. Hyderabad, India
Neptune Stampings, Vadodara, India
Patson Transformers, Gujarat, India
Star Delta Transformers, Shopal, India
Uttam Electricals Ltd., Jaipur, India

South America
Caivet Transformadores, Caracas, Venezuela
CNS, Sao Paulo, Brazil
INATRA, Guyaquil, Ecuador
Rhona S.A., Vina Del Mar, Chile
Rymel Engenieria Electrica, Itaqui-Autoquia, Colombia
Siemens, Bogota, Colombia

Africa
Alloy Magnetic Cores, Elsburg, South Africa
Areva, Johannesburg, South Africa

19

DUO & DG
core

North America
ABB Inc, Jefferson City, Missouri, USA
Ambar Electroingenieria, Ecatepec, Mexico
BCL Magnetics, Burlington, Ontario, Canada
Carte International, Winnipeg, Canada
Condumex, Laredo, Mexico
CorMag, Burlington, Ontario, Canada
Eaton Electrical, Arden, North Carolina, USA
El-Met-Parts, Dundas, Ontario, Canada
Electromagnetic Ind., Clearwater, Florida, USA
Instrument Transformers, Clearwater, Florida, USA
Kuhlman Electric Corp., Versailles, Kentucky, USA
LakeView Metals Inc., Winthrop Harbor, Illinois, USA
Magnetic Metals, Anaheim, California, USA
Pauwels Transformers, Missouri, USA
Power Magnetics, Gardena, California, USA
Prolec GE, Apodaca, Mexico
TC Metals, City of Commerce, California, USA

Unicore
machine

Europe
ALCE Elektrik, Turkey
Elettromeccanica Zucchiatti, Pordenone, Italy
Elesa Transformadores, Spain
MAKITEL DOOEL, Ohrid, Macedonia
Superfin, Berlin, Germany / INTEPS, Pskov, Russia
Vakar, Dobr, Czech Republic
VP Technotron, Frdek-Mstek, Czech Republic

Basic
info

Some references

DUO transformer used for vacuum tube amplifier

DUO
assembly

Other
cores

20 kVA transformer
with DG core, Slovakia

Cruciform 630 kVA DUO2 core from 8 strips

Agent for Europe

Subagents in Europe

Ruff s.r.o.
Tyrova 1033, 744 01 Frentt p. R.
Czech Republic
Tel.: +420 608 834 747
Fax: +420 556 831 701
info@ruff.cz
www.ruff.cz
Austria, Germany & Switzerland
Schppi Industrievertretungen
Geissweidli 5
CH-8846 Willerzell
Tel./Fax: ++41 55 422 00 40
Tel.: ++41 79 620 35 47
pschaeppi@bluewin.ch

France
Mrs. Lydia Cayeux
15, chemin des Beaudenons
45220 St Germain des Prs
Tl.: ++33 2 38 94 63 32
Fax: ++33 2 38 94 64 01
cayeux.tct@wanadoo.fr

Russia
TC Windeq
Domodedovskoe shosse, 1/3
Moscow 142116
Tel.: ++79 261 939 494
Tel.: ++79 263 789 898
info@windeq.com

Turkey
UYGAR Teknoloji Mhendislik
Elektrik Makineleri
San. ve Tic. Ltd. Sti.
1420 Sokak No: 30/1-1
35220 Kahramanlar-IZMIR
Tel.: ++90 232 445 51 62
Fax: ++90 232 445 51 63
uygartekno@superonline.com

Spain
MPTECNOIMPORT, S.L.
Nord, 76 Local 20
08950 Esplugues de Llobregat
Tel.: +34 93 473 7975
Fax: +34 93 473 7992
info@mptecnoimport.com

layout & printing: www.loksaprepress.cz

AEM Cores Pty. Ltd.

95 Bedford Street, Gillman
SA 5013, Australia
Tel.: +61 8 8341 0086
Fax: +61 8 8341 0225
sales@aemcores.com.au
www.aemcores.com.au