DFE 

Energy Saving 3D Wound Core Distribution Transformer Technology 
for power grid efficiency and Power Line Losses

Eng. Jiang Pengfei

MENA Market CEO
(CMO and MBA)

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 Part I Distribution Transformer

Laminated Core Distribution Transformer

Laminated Core Distribution Transformer  Function Voltage transformation

No Load Loss and Load Loss

Reducing no Load Loss in design 

Maximum efficiency at lower load

Minimum voltage regulation  
Laminated Core Active Part Distribution Transformer
Small leakage reactance
Since 1881, more than 100 years

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 Part I Distribution Transformer

3D Wound Core Distribution Transformer

Theory: the optimal 3 phase 

Laminated Core‐Magnetic Path Direction
transformer should have a 
symmetrical delta‐shaped (3D) 
core
3D‐Wound core‐Magnetic Path Direction
No manufacturing technology 
available to make it with lower 
cost

In china, DFE Realized this 
theories by normal materials and 
precision produce equipment 
and precision process

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 Part I Distribution Transformer

3D Wound Core

Upgrade all the laminated 
transformers for energy‐saving by 
the end of 2017 in China Power 
Grid.

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 Part II 3D Wound Core Technology Advantages

Advantage 1 – Balanced and optimization Magnetic circuits in all 3 phases

Laminated Core  Laminated Core Vector  Diagram 3D Wound Core

3D Wound Core Vector Diagram
magnetic flux distribution magnetic flux distribution

Phase magnetic circuit Completely symmetrical 
The shortest length of the three‐phase magnetic circuit 
The Phase magnetic circuit length exactly equal 

magnetic flux and  silicon Crystals 
magnetic circuit distributed 
Seamless phase magnetic circuit 
in the same direction
evenly and density no distortion

Laminated Core Angle Map Laminated Core magnetic flux Distribution 3D Wound Core magnetic flux Distribution 3D Wound Core Angle Map

2017‐5‐11 15:12 No obvious high resistance region 5/34

 Part II 3D Wound Core Technology Advantages

Balanced exciting current in all 3 phases

16 3‐phase magnetic flux uniform distribution
14
Balance in 3 Phases
No‐Load Current(mA)

12

No obvious high resistance region, 
10
3D Wound Core reduce no‐load loss and no‐load current. 
8
Laminated Core
6

4 Three‐phase magnetic circuit completely 
2 symmetrical, and the three‐phase no‐load 
current is completely balanced.
0 (Phase)
A B C
No‐Load Current Balance in 3 Phases 

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 Part II 3D Wound Core Technology Advantages

Advantage 2- Reduced in-rush currents and exciting currents

Filling coefficient as high as 99% ,
far higher than the laminated core 

Shorten 2‐3% length of copper wire ,
save2-3% copper

Net section filling coefficient>0.99 Net section filling coefficient>0.90
Reduce the winding resistance to reduce 
the copper loss.
3D Wound Core Stem section Laminated Core Stem section

almost like a circle  like trapezoid 

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 Part II 3D Wound Core Technology Advantages

Advantage 3 – Reduced vibrations and noise and low electric field

 Magnetic circuit coherent
 Tightly rolled
 The flux density is low

Reduce noise 15‐20db.

Laminated Core        3D Wound Core

The Noise Figure to Comparison

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 Part II 3D Wound Core Technology Advantages
Advantage 4-Better short circuit withstanding and resistance capability

Low heating capacity:
 no‐load loss  very small
 no‐load current very small 

Natural circulation & natural ventilation 
formed in the coil center

Good acid and alkali resistant 
Fire and damp‐proofing
Low partial discharge 

Clamping device welded into a whole to 
improve the overall strength and 
deformation.

Short circuit resistance capability‐very 
important for the power grid stable 
operation

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 Part II 3D Wound Core Technology Advantages

Advantage 5- Reduce No load loss and No load current

4 no use Corner If the weight of core gets down, the no‐load loss is down
Formula: P0 =K0 G Pt
Pt means the unit weight loss of the core（Bt）
K0 is technological coefficient
Seam G is the overall weight of the core

Saving 20%  Silicon Steel and 2‐3% Copper Wire

No load loss reduced by 30%
Comparing Condition：
 Same silicon sheet material
 Same area of the stem cross section No load current reduced by about 70%
 Same size of the window
 Same center to center spacing of the stem Load Loss reduced by 5‐10%

2017‐5‐11 15:12 10/34

 Part II 3D Wound Core Technology Advantages

Advantage 5- Reduced 3rd harmonic effects and total harmonics distortion

Harmonic problems can cause a lot of harm:
‐ Reduce the capacity of systems (transformers, 
circuit breakers, cables, etc.)
‐ To accelerate equipment aging, shorten equipment 
life, and even damage equipment
‐ Endanger production safety and stability
‐ Waste energy
‐ attracted people's attention

Better wave form, no the third harmonic, improve the 
power factor; improve the quality of power supply

3D Wound Core Harmonic  Map

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 Part II 3D Wound Core Technology Advantages
3rd Harmonics and Total Harmonics Distortion at No-load

79.40
80.00
3D Wound Core
40 36.4 70.00
Laminated Core
35 3D Wound Core
29.5 60.00 54.40

Harmonics Content(%)
51.40
Laminated Core
30
Harmonics Contrnt(%)

50.00
25
40.00
20 28.40 28.60
26.00
30.00
15 11.2
20.00
10

5 10.00
0.7 0.7 0.1 (Phase)
(Phase) 0.00
0
A B C A B C

3rd Harmonics at No‐load Total Harmonics Distortion at No‐Load

Notes: All Data from 225kVA 3D wound Core Transformer and 2D Laminated Core under specific 
operating conditions unless otherwise stated.

2017‐5‐11 15:12 12/34

 Part II 3D Wound Core Technology Advantages

Advantage 6- Natural ventilation cooling structure

Natural circulation and natural ventilation

3D Wound Core ventilation cooling structures are 
superior to the Laminated Core, accord with the 
principle of heat exchange.

3D Wound Core ventilation cooling structure

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 Part II 3D Wound Core Technology Advantages

Advantage 7- Save installation Space and convenient maintenance.

Compact Product structure and small footprint

 Body plane area less 10‐15% than laminated products
 Body height less 10‐20%
 Cabinet substation box  volume less nearly 25%.

H pole beams On ground
315‐1250 kVA 315 ‐2000 kVA

Cabinet substation box

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 Part II 3D Wound Core Technology Advantages

Advantage 8 - High production efficiency and consistency

Digital‐Controlled

3D Wound Core made by winding Machine

DFE EAJ‐880 3D Wound Core 
Automatic Making Machine

Manpower Cost Saving  ‐ 5000Nos/100Workers/Year Laminated Core made by hand

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 Part II 3D Wound Core Technology Advantages
Advantage 8 - High production efficiency and consistency

Digital‐Controlled

DFE EAR‐800 Automatic Coil 
winding Machine Foil and Coil Winding 

Manpower Cost Saving  ‐ 5000Nos/100Workers/Year

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 Part II 3D Wound Core Technology Advantages

Advantage 9- 3D Wound Core Anti-Theft

Not easy to separate the silicon steel  and the copper wire Easy to separate the silicon steel and the copper wire

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 Part II 3D Wound Core Technology Advantages
Advantage 10-3D Wound Core especially suitable for medium and small transformers.

□ Power Capacity   30KVA to 2500KVA □ Voltage  35kV 33 kV 11kV 10.5kV 10kV 6kV

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 Part III 3D Wound Core Technology Benefits

Benefits 1 - For Electricity Company and Electricity Customers

120%
3D  Wound Core Standard loss
Energy Saving Transformer transformer
100% Increased electricity saving 

80%
3D Wound Core Energy Saving 
Transformer saves 43% more 
60%
than standard loss transformer 
in electricity cost from total 
40%
transformer loss reductions in 
20%
5 years

0%

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 Part III 3D Wound Core Technology Benefits

Benefits 1 - For Electricity Company and Electricity Customers

Lower Total Owning Cost (TOC)

TOC of 3D Wound Core Energy 
Saving Transformer over a 20 
year period is 28% lower than 
that of standard loss transformer.

2017‐5‐11 15:12 20/34

 Part III 3D Wound Core Technology Benefits

Benefits 1 - For Electricity Company and Electricity Customers

5 year Return on Investment (ROI)

Price of 3D Wound Core Energy 
Saving Transformer minus 5 years 
electricity cost savings from total 
transformer loss reductions is 
equal to price of standard loss 
transformer.

2017‐5‐11 15:12 21/34

 Part III 3D Wound Core Technology Benefits

Benefits 2- Benefits for Reduced CO2 emissions and trees to offset CO2 emissions

35,000 CO2 Emissions Trees required to offset CO2 emissions

30,000

25,000 800
700
20,000 600

Mature Tree/Year
Kg/Year

500
791
15,000 400
30,862
300 449
10,000 200
17,529
100
5,000
0
3D Wound Core Energy Saving Convenstional Laminated Core
0 Transformer Transformer

3D Wound Core Energy Saving Convenstional Laminated Core
Transformer Transformer
3D Wound Core Energy Saving Transformer emits 43%
Remarks: All comparisons made using a 1000kVA 3D Wound Core  less CO2 and requires 43% less trees to offset CO2 
Energy Saving Transformer (European standard Ao + Ak losses) and 
conventional laminated core standard loss transformer under specific  emissions than the standard loss transformer 
operating conditions unless otherwise stated. (calculated at 80% average load)
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 Part IV Energy efficiency promotion policy

Distribution transformer energy efficiency promotion policy in the World

For energy saving and emission reduction, many 
countries issue a policy to improve distribution 
transformers efficiency.

As early as 1998,the United States launched 
“the Energy Star Transformer Program”

In 2005, the European Union launched “the 
Distribution Transformer Promotion Partner 
Program"

In 2006 ,Japan to implement “ the Transformer 
energy efficiency leader program".

In 2014, China made “Distribution Transformer 
Energy Efficiency Promotion Plan(2015‐2017)

2017‐5‐11 15:12 23/34

 Part VI DFE 3D Wound Core Transformer Technology

DFE 3D Wound Core Transformer Factory

DFE Value

DFE Solution
Supply 3D Wound Core Distribution 
No Video Transformer as local Standard 
requirement to decrease power line 
loss with EPC+F

Transfer DFE 3D Wound Core 
Technology and Produce line to local  
transformer factory 

Supply Distribution Transformer LCM  
and O&M 

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 Increase power grid efficiency and decrease power losses
By DFE Electricity Technology

Email: dfescada@163.com

Egypt Mobile:+201022877898

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