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A CORE PART OF:

EFFICIENT ENERGY DISTRIBUTION

INNOVATING TRANSFORMERS

YOUR OPERATIONAL SUCCESS

Unicore catalogue
the range and the facts

Contents
Unicore products . ......................................................................................................................................................................... 10
UCM3000..................................................................................................................................................................................... 10
UDM4000.....................................................................................................................................................................................11
DUO Core.....................................................................................................................................................................................12

Single Phase . .......................................................................................................................................................................12

Three Phase . ........................................................................................................................................................................13

Distributed Gap Cores ............................................................................................................................................................13


Cruciform ....................................................................................................................................................................................14
Stepbutt ......................................................................................................................................................................................14
Butt-2 Core & Butt-3 Core ......................................................................................................................................................15
Gapped Core . ............................................................................................................................................................................16
Uncut Core . ................................................................................................................................................................................16
Dee Core . ....................................................................................................................................................................................17
Straight Laminations ...............................................................................................................................................................17
Unicore manufacturing examples . ..........................................................................................................................................18
Assembly of Unicores ...................................................................................................................................................................19
Single Phase DUO Core ..........................................................................................................................................................19
Three Phase DUO Core . ........................................................................................................................................................ 20
Single Phase Distributed Gap ............................................................................................................................................. 21
Cruciform ................................................................................................................................................................................... 22
Examples of transformers .......................................................................................................................................................... 23
Customer references .................................................................................................................................................................... 26
Unicore Customers ................................................................................................................................................................. 26
Agents ......................................................................................................................................................................................... 27

INTRODUCING
OUR CORE VISION

Since 1958 AEM has been driven by the vision to improve


the efficiency of transformer core technology
throughout the entire value chain. This means better
manufacturing machines, better core products and
better performance in the field.
With the cleantech age upon us, our original ideals
have proven to be far ahead of the times. AEM is firmly
committed to continue as a leader in highly efficient
core technologies.

Generating efficiency in 3 key areas

core
manufacturing

UNICORE
PRODUCTS

IN THE
FIELD

Reduce manufacturing foot print


and delay investment
into larger machines

Easy and affordable design,


assembly and manufacture

Proven performance to improve


distribution efficiency

A core part of
the bigger issues

Climate change is driving economies and


technologies to be more efficient, eliminate
waste, reduce carbon emissions and
provide sustainability.
Whether you believe in climate change
or not, is not the issue. Carbon emission
schemes and taxation will affect believers
and non-believers alike, we will all pay, and
hence must play a part.
AEM has been producing high quality cores
and core machines long before the term
carbon credits was created. Our core value
is to vastly improve efficiencies throughout
the significant value chain that has been our
focus since 1958.
Our Unicore products and manufacturing
machines are now the preferred choice
for many small, medium and multinational
transformer manufacturers world wide.
With such significant acceptance, we see
the opportunity to enhance our part in the
energy industry.
Helping you play an even bigger part in the
overall energy and cleantech solution.

A core part of

For General Purpose and Distribution Transformers our core products


have enhanced efficiency in many ways
Unicores hold a number of advantages over other types
of magnetic cores for general purpose and distribution
transformers. With lower loss, efficient production and
ease of assembly, our Unicores have helped innovate
transformers around the world.
The gap has widened even further with the DUO core,
which not only provides exceptional energy efficiency,
it is also very simple to assemble. The future for DUO
core will be to replace large E&I, strip laminations and
C cores, which struggle to meet the need for greater
energy efficiency.

Our comprehensive range of Unicores


Each type is able to be customised and made to exacting
specifications.








DUO core
Distributed gap cores
Cruciform
Stepbutt
Butt cores
Gapped core
Uncut core
Single phase
Three phase

OUR EXPERTISE HAS DEVELOPED A Range of unicores,


based on three key criteria:

Must be the most efficient


in terms of
reducing core loss

Must perform with


low loss and affordability

Must be easy to use,


install and handle

innovating transformers

PERFORMANCE
Typically used for distribution and general
purpose transformers from 1000 VA to 1500
kVA or more.

MATERIALS
Produced from any grade of Grain Oriented
Silicon Steel (GOSS). Thickness from 0.2 to
0.35 mm. Strip width from 20 to 300 mm.

Strip Width

GEOMETRY & SIZES

Window Length
Build-up

Window Width

Weight: Up to 1500kg
Unicore faces: Distributed gap, DUO core,
straight butt or uncut
Corners: 30, 45, 90 - depending upon application
Simple to specify and produce to suit your design.

Parameters
Window Length (WL)
Strip Width (SW)
Strip Thickness (ST)

Window Width (WW)


Build-up (BU)
Corner Angle

A core part of

The lasting passion for continual efficiency that began in 1958


In fifty years we have gone from a manufacturer of arc
welders to a leading global supplier of Unicore machines
and Unicores. The one thing that has been common
throughout the journey has been the question, how to
improve efficiency at each and every step?
The small size of the Australian transformer core
market inspired AEM to develop flexible automated
machinery for core manufacture. The company was
also committed to innovating core design.

are prime examples of improving efficiency.

Over 200 Unicore machines sold globally


Unicore machines eliminate the need for fixed tooling
such as jigs and mandrils. Unicore laminations are fully
formed by the machine.
For the operator, flexibility, accuracy and reliability are
key advantages. Reduced core/coil assembly time
results in reduced transformer costs.

The result has been the creation of Unicore machines


that produce the exceptional Unicores. Unicores are
highly regarded in the market as the most advanced
and efficient available. And the machines themselves

Manufacturing high quality


cores has never been easier

Fully programmable for flexible production


Produce fully formed cores
Eliminate manual forming
Reduces need for annealing
Minimises core loss
Automated, with no tooling required
Just-in-time production runs
Convenience of smaller size, less weight
Superior product, with same affordability
Easier to handle and store

Before you buy a large


expensive core machine...

AEM Unicore machines have minimal footprint


They are highly affordable
Require minimal inventory
Multiple machines vastly increase production
capacity for far less cost
Delay extensive capital investment

your operational success

Simple and flexible production


The core design screen offers a simple GUI for operators to
make selections, configure and produce at a rate that suits
your requirements

High speed
production for
Just-in-Time
performance
A spreadsheet is available
to calculate core production
times.

Reduce annealing
costs
Unicores are fully formed
by the machine.
Annealing will reduce core
loss on small to medium
sized cores but costs can
be saved if this is not
necessary. Large Unicores
have very low loss, so
annealing costs can be
saved.

ROI can be as low


as 6 to 9 months
9

UCM3000
AEM UNICORE UCM3000

FOR GENERAL PURPOSE AND


DISTRIBUTION TRANSFORMERS

Description
In the 10 years since its introduction Unicore
technology has been proven and accepted in
over 30 countries worldwide.
From small specialists to large
multinationals, Unicore is the preferred
technology.

10

unicore products

UDM4000
AEM UNICORE UDM4000

Description
Suitable for most industries requiring decoilers
Push button hydraulic expanding mandrel
Maximum coil width 450 mm
Maximum coil weight 2000 kg
Maximum mandrel diameter 525 mm
Minimum mandrel diameter 460 mm
Speed range 5-30 rpm by VF drive
Strip sensing non-contact induction sensor
Power 380-5000 VAC 3 ph
Can be powered from the AEM Unicore machine

Hydraulic Expansion Mandrel

Non-contact Induction Sensors

Typical Installation

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duo core
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
Distribution and General Purpose Transformers. Annealed
DUO cores with one lamination per overlap will have the
lowest core loss. After assembly into windings TIG welding
of the last lamination and wedging is recommended.

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
magnetising VA will increase.

DUO Sizes
Dimension

Minimum (mm)

Maximum (mm)

Window Length (WL)

80

Unlimited*

Window Width (WW)

40

Unlimited*

Strip Width (SW)

20 (with two strips)

300 (with one strip)

Build Up (BU)

Material Thickness

Unlimited*

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


manufacturing considerations.

Optional Annealing
Annealing reduces losses by 5 to 30%, depending on the
core size.

Material

No Banding

Any grade of GOSS, thickness 0.2 to 0.35 mm.

Simple TIG weld of final lamination only.

SINGLE PHASE
single phase

Description
DUO Core is very suited to Core Type Single Phase
Transformers. When used for Shell Type, the core leg outside
the coils should be held tight.

12

unicore products

three phase
Three phase

Description
DUO Cores are very well suited to Evans style (Core Type)
Three Phase Transformers. They are also very good for the
inner cores of a 4 core / 5 limb transformer.

distributed gap
distributed gap cores

Application

Optional Annealing

DG Unicores represent a family of cores with a single cut


per lamination. They are used for single-leg and shell type,
single and 3-phase Distribution Transformers.
Unlike traditional technology of producing DG cores, no
tooling is needed for production of DG Unicores.

Annealing reduces losses by


5 to 30% depending on the
core size and is almost always
desirable to achieve the
highest efficiency.

DG Unicore Types
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.

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

DG Unicore Sizes
Dimension

Minimum (mm)

Maximum (mm)

Window Length (WL)

60

Unlimited*

Window Width (WW)

40

Unlimited*

Strip Width (SW)

20 (with two strips)

300 (with one strip)

Build Up (BU)

Material Thickness

Unlimited*

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


manufacturing considerations.

13

cruciform
cruciform

Description
For use with round coils a Unicore may be made from
multiple strip widths. The resultant core legs have a
cruciform cross section.

stepbutt
stepbutt

Description
This type of Unicore is used only for a shell type General
Purpose Transformers to replace laminations, up to approx.
2 kVA. Its losses are much higher than DUO or DG Unicores,
lower than or comparable to a C core but much lower than
laminations.

14

unicore products

Butt coreS
butt-2 core and BUTT-3 CORE

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

15

gapped core
gapped core

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

uncut core
uncut core

Description
It is a core with no cuts. The Unicore machine is only feeding
and folding steel.
Uncut cores are used for Current and Voltage Transformers.
They are always annealed to achieve the lowest loss and
magnetising current.

16

unicore products

DEE core
DEE core

FOR VOLTAGE TRANSFORMERS


Description
DG core with unequal corner sizes promotes
uniform shrinkage of resin, reducing the likelihood of
voids forming.

STRAIGHT LAMINATIONS
STRAIGHT LAMINATIONS

Description
The Unicore machine can be programmed to
produce rectangular 90 cut laminations which
can be used for the manufacture of chokes and
transformers.

17

manufacturing examples

manufacturing
manufacturing

Vakar, Czech Republic

INTEPS, Russia

Makitel, Macedonia

Therma FM, Czech Republic

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Assembly of Unicores

single phase
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.

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

Male half of the core

Taking a male packet

Partly assembled core


without bobbins

Taking a female packet

DUO3 detail

Assembly plates

19

Assembly of Unicores

three phase

three phase duo CORE assembly

Procedure
Assembly of a three phase DUO core is very similar to
the single phase 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 and wedge firmly in the
outer coils. Then weld.

Example of a Cast Resin Transformer


Core weight: 164 kg
Transformer power: 50 kVA
Core production time: 41 min
Core assembly time: approx. 50 min
An assembly table

First inner core


assembled

Inserting first lamination


Strapping the core

Inserting female packet

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Wedging the inner cores

Start of outer core assembly

Assembly of Unicores

single phase

single phase distributed gap CORE

25 kVA Core Type Dry Transformer With DG Core


Core size (DG): WL 300, WW 160, SW 130, BUP 67
Core weight: 73 kg
Core production time: 21 min
Core assembly time: approx. 45 min

21

Assembly of Unicores

cruciform
cruciform CORE assembly

25 kVA Dry Distribution Transformer With DDG


Core
Core size (DDG): WL 280, WW 128,
SW 60/90/120, BU 116mm
Core weight: 152 kg
Core production time: approx. 70 min
Core assembly time: approx. 60 min

100 kVA Distribution Transformer With


DUO2 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 min

22

examplesunicore
of transformers
products

transformers
DISTRIBUTION transformers

100 KVA transformer, Italy

10 mVA transformer,
South Africa

4-core 5-limb 3-ph


transformer, Australia

Three phase 100 kVA transformer,


Poland

23

examples of transformers

transformers
GENERAL PURPOSE transformers

Core type
transformer

Shell type transformer


with DUO cores, Russia

Single-leg transformer

24

examplesunicore
of transformers
products

transformers
Voltage / Potential Transformers

Medium voltage transformer

Shell-type DUO core


transformer, Italy

25

customer references

unicore customers
unicore customers

Australia & New Zealand

North America

ABB Australia Pty Ltd, Darra, New South Wales


AEM Cores Pty Ltd, Gillman, South Australia
ETEL Distribution Transformers, Auckland, New Zealand
Thycon Industries Pty Ltd, Coburg, Victoria
Tyree Transformers, Mittagong, New South Wales

ABB Inc, Jefferson City, Missouri, USA


Ambar Electroingenieria, Ecatepec, Mexico
BCL Magnetics, Burlington, Ontario, Canada
Carte International, Winnipeg, Canada
Central Moloney Inc., Pine Bluff, Arizona, USA
CG Power Systems USA Inc, Washington, Missouri
Cogent, Ontario, Canada
Corte de Nucleos, Temoaya, Mexico
Eaton Electrical, Arden, North Carolina, USA
El-Met-Parts, Dundas, Ontario, Canada
IEM/Condumex, Tlalnepantla, Mexico
Instrument Transformers, Clearwater, Florida, USA
Jaro Electronics, Basseterre, St Kitts
LakeView Metals Inc., Winthrop Harbor, Illinois, USA
Power Magnetics, Gardena, California, USA
Prolec GE, Apodaca, Mexico
TC Metals, City of Commerce, California, USA
Transformadores IMEM, Celaya, Mexico
Vicksmetal, Vicksburg, Mississippi

Asia
ETAH Sdn. Bhd., Kuala Lumpur, Malaysia
Han Chang Transformers, Korea

India
Alfa Transformers Ltd, Gujarat, India
Alfa Transformers Ltd, Orissa, India
B.R. Industries Ltd, New Delhi, India
Danish Private Limited, Jaipur, India
Danke Products, Gujarat, India
East India Udyog Ltd, Uttar Pradesh, India
Genus Overseas Electronics, Jaipur, India
Huphen Transformers, Maharashta, India
Jupiter Electricals, Gujarat, India
Kalpana Industries, Jhunjhunu, India
Kotsons Pty Ltd, Agra, India
Kryfs Power Components Limited, Mumbai, India
Mangal Electrical Industries, Jaipur, India
Manu Power Equipments Pty Ltd, Hyderabad, India
Neptune Stampings, Gujarat, India
Nucon Switchgears Pty Ltd, Punjab, India
Patson Transformers Pty Ltd, Gujarat, India
PME Transformers (India) Limited, Uttar Pradesh, India
RTS, Jaipur, India
Sangrur Industrial Corporation, Punjab, India
Shirdi Sai Laminations, Andhra Pradesh, India
Shri Krsna Sudarshan Urja Pty Ltd, Jaipur, India
SPI Containers, Gujarat, India
Star Delta Transformers Ltd, Bhopal, India
SVR Electricals (P) Ltd, Andhra Pradesh, India
Swastik Copper (P) Ltd, Jaipur, India
Technical Associates Ltd, Uttar Pradesh, India
Uttam (Bharat) Electricals (P) Ltd, Jaipur, India

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

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South America
Caivet Transformadores, Caracas, Venezuela
CNS, Sao Paulo, Brazil
Corporacion Iadiexport, Venezuela
Ecuatran SA, Ambato, Ecuador
Frana International Ltda., Bogota, Colombia
INATRA, Guyaquil, Ecuador
Rhona S.A., Vina Del Mar, Chile
Rymel Engenieria Electrica, Itaqui-Autoquia, Colombia
Siemens, Bogota, Colombia

Europe
ALCE Elektrik, Pendik, Turkey
ArcelorMittal, Frydek-Mistek, Czech Republic
Elektromashina, Kemerovo, Russia
Elesa Trasformadores, Zarautz, Spain
INTEPS, Pskov, Russia
Makitel, Ohrid, Macedonia
Metod, Sobinka, Russia
Pskovelektrosvar, Pskov, Russia
Russian Transformer, Samara, Russia
Stalprodukt, Bochnia, Poland
Therma FM, Przno, Czech Republic
Traser, Serravalle Scrivia, Italy
Vakar, Dobra, Czech Republic
Zucchiatti Elettromeccanica, Pordenone, Italy

AGENTS

AGENTS
AGENTS

Head Office

Europe

AEM Cores Pty Ltd


95B Bedford Street
Gillman, South Australia 5013
T: +61 8 8341 0086
F: + 61 8 8341 0225
E: sales@aemcores.com.au
W: www.aemcores.com.au

AEM Europe
Tyrova 1033, 744 01 Frentt p.R.
Czech Republic
T: +420 608 834 747
E: unicore@ruff.cz

North America
Unicore Machines (USA) LLC
20 Hoiles Drive, Unit B, Right Side,
Kenilworth, New Jersey 07033 USA
T: +908 245 0566
F: +908 245 1770
E: mmayer@unicoremachines.us

India, Bangladesh, Pakistan, Sri Lanka


AEM Unicore Machinery India
A-186 Telephone Exchange Lane
Mahipalpur, New Delhi 110037 India
T: +91 11 41019214/26784948
F: +91 141 26781405
E: aem_india@yahoo.com

South America
Frana International Ltda.
Cra. 127 No. 15B-40 Interior 4 Bodega 4
Bogota, Columbia
T: (571) 298 6852-298 6791
E: frana@franainternational.com

Japan
Kisco Ltd
2-9-25 Tatekawa, Sumida-Ku, Japan
T: 03 5600 6222
F: 03 5600 6226
E: tsuto@kisconet.co.jp

Africa
Alloy Magnetic Cores (AMC)
Cnr. Simon Bekker & Crompton Street
Germiston South, Johannesburg, South Africa
T: +27 11 825 1010
F: +27 11 825 1045
E: sales@amccores.com.au

Technical Consultant for Cast Resin and


Oil Type Distribution Transforner
Mr. Ergin Dikmen, Turkey
E: ergindikmen_@hotmail.com

Subagents in Europe
Austria, Germany & Switzerland
Schpppi Industrievertretungen
Geissweidli 5
CH-8846 Willerzell
T/F: ++41 55 422 00 40
T: ++ 41 79 620 35 47
E: pschaeppi@bluewin.ch

Russia
TC Windeq
Domodedovskoe shosse, 1/3
Moscow 142116
T: +495 543 72 60
F: +495 542 20 85
E: info@windeq.ru

Spain
MP-TECNOIMPORT, S.L.
Nord, 76 Local 20
08950 Esplugues de Llobregat
T: +34 93 473 7975
F: +34 93 473 7992
E: info@mptecnoimport.com

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

27

95B Bedford Street


Gillman South Australia 5013
T +61 8 8341 0086
F +61 8 8341 0225
sales@aemcores.com.au
www.aemcores.com.au

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