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Silicon steel toroidal core is an essential material in the realm of electrical engineering, playing a significant role in various applications that rely on efficient electromagnetic properties. These core, designed in a toroidal (doughnut-like) geometry, is often crafted from high-quality silicon steel materials to show unparalleled magnetic characteristics. This makes the core indispensable in the design and production of transformers, inductors, sensors, and other electrical devices.
Additionally, the unique toroidal shape design sets it apart from the conventional E-I core, offering distinct advantages in terms of efficiency and performance. For example, the circular or donut-shaped structure allows for a continuous magnetic path with minimal air gaps or flux leakage, resulting in superior energy efficiency and reduced losses.
Silicon Steel Toroidal Core Types
Generally speaking, silicon steel toroidal core can be divided into grain-oriented and non-oriented types based on the material.
Grain-Oriented vs. Non-Oriented: The toroidal core can be made from grain-oriented silicon steel, which has its grains aligned to enhance magnetic properties in a specific direction, or non-oriented silicon steel, which has a random grain structure that provides uniform magnetic properties in all directions.
Dimension Range:
– Strip width: minimum 3mm
– Inside diameter: minimum 5mm
– Outside diameter: minimum 8mm, maximum 1100mm
| Toroidal Cores Tolerance (mm) | ||||
| Outside Diameter | Inside Diameter | Height | ||
| OD | △D | ID | △d | △h |
| ≤10 | ±0.4 | ≤10 | ±0.30 | ±0.3 |
| ≤25 | ±0.5 | ≤25 | ±0.40 | ±0.3 |
| ≤50 | ±1.0 | ≤50 | ±0.50 | ±0.4 |
| ≤80 | ±1.0 | ≤80 | ±0.75 | ±0.5 |
| ≤100 | ±1.0 | ≤100 | ±0.80 | ±0.5 |
| ≤160 | ±2.0 | ≤160 | ±1.30 | ±0.8 |
| ≤200 | ±2.5 | ≤200 | ±1.50 | ±1.5 |
| ≤320 | ±2.5 | ≤320 | ±2.00 | ±2.0 |
| ≤500 | ±3.5 | ≤500 | ±2.50 | ±2.5 |
| ≤800 | ±5.0 | ≤800 | ±3.50 | ±3.0 |
| ＞800 | ±7.5 | ＞800 | ±5.00 | ±4.0 |
Besides, our finished silicon steel toroidal cores can be supplied in various finish treatments:
– Natural (dry).
– Edge bonded, for protection from mechanical stresses.
– Fully vacuum impregnated, for greater protection from mechanical stress.
– Polypropylene covered, for electrical insulation.
– End capped, for greater electrical insulation.
– Epoxy coated, for electrical and heat insulation.
– Painted, for added corrosion protection and cosmetic purposes.
Silicon steel toroidal cores offer several advantages over traditional shapes like E-I cores.
1. Toroidal Design
The toroidal shape, which resembles a doughnut, offers several advantages over traditional rectangular or cylindrical cores.
Firstly, the toroidal design features a closed-loop structure that encircles the windings. This design eliminates air gaps and minimizes leakage flux, resulting in enhanced efficiency and reduced electromagnetic interference. Moreover, the continuous circular shape of the core ensures a uniform magnetic path for the flux, leading to enhanced inductance and improved performance in terms of energy transfer and overall stability. Additionally, this shape also reduces the volume of material needed for the core compared to traditional designs.
2. Improved Magnetic Performance
Made from silicon steel alloy, this material exhibits enhanced magnetic properties like:
High magnetic permeability: The silicon steel has high magnetic permeability, which can effectively conduct and concentrate the magnetic field. This allows the core to transmit and convert energy more efficiently and improve energy conversion efficiency.
Low Energy Losses: The use of silicon steel significantly lowers hysteresis losses and eddy current losses, making toroidal cores highly efficient, especially at high frequencies.
High saturation magnetic induction intensity: The silicon steel material often has a high saturation magnetic induction intensity. Saturation magnetic induction intensity refers to the maximum magnetic induction intensity that the material can withstand when it is saturated. The high saturation magnetic induction intensity of the silicon steel toroidal core enables the electrical device to withstand high magnetic flux density and improve energy transmission efficiency.
3. Compact and Lightweight
Toroidal cores are often more compact and lighter than laminated cores, allowing for smaller designs with similar or improved magnetic performance.
The compact nature of the toroidal core also helps in reducing space requirements, making it ideal for applications where size constraints are a concern.
4. Low Noise and Vibration
Silicon steel toroidal cores also exhibit lower audible noise levels compared to silicon steel E-I cores during operation.
The absence of air gaps in toroidal cores minimizes vibrations and mechanical stress, thus reducing the noise level of the equipment and improving the stability and reliability of the equipment. This makes it much more suitable for noise-sensitive environments such as residential areas or office spaces.
5. Easy Processability
Additionally, their special design and compact size make them easier to install and handle during assembly processes. For example, the toroidal shape allows for easier winding of wire around the core, which can simplify the manufacturing process for transformers and inductors.
6. Lower Electromagnetic Interference (EMI)
The closed-loop design also provides better electromagnetic shielding, reducing interference with nearby electronic components and improving overall system reliability. Therefore, silicon steel toroidal cores can exhibit lower levels of electromagnetic interference (EMI) and vibrations due to their compact design.
7. Thermal Stability
Moreover, the symmetrical shape of the toroidal core allows for more efficient heat control compared to other core shapes. The uniform distribution of heat across the entire circumference facilitates better thermal management, ensuring optimal operating conditions and prolonging the lifespan of the electrical device.
8. Customized Solutions
Silicon steel toroidal cores manufactured from Gnee Steel are rolled by the independently developed high-precision winding machine and finalized by high vacuum heat treatment. They have stable performance, good linearity, precise size, and unlimited shape. Importantly, customized designs can be made to meet customer’s drawings. If interested, feel free to contact us for more details~
Applications
Silicon steel toroidal cores are primarily used in transformers, inductors, and other electrical components where compact size and efficient magnetic coupling are desired. Here are some examples for reference.
1. Inductors and Chokes: Commonly used in electrical circuits for energy storage and filtering, such as power supplies, energy storage systems, audio equipment, and RF applications.
2. Transformers: Suitable for applications like switch-mode power supplies (SMPS), audio transformers, and isolation transformers, where high efficiency and reduced size are crucial.
3. Magnetic Sensors: Employed in various types of sensors where an efficient magnetic field response is necessary, such as in proximity sensors and position detection systems.
4. Power Electronics: Used in electronic devices that require efficient energy conversion and minimal losses, such as inverters and converters.
5. High-Frequency Devices: Effective in RF applications due to their low losses and ability to handle high frequencies without significant degradation in performance.
