The conventional way of building stacked transformer cores is a tedious and time-consuming operation. Conventional cores are constructed by using layers of thin sheets of magnetic material with each layer overlapping the previous one. The large size of some transformer cores leads to relatively long construction times resulting in significant contribution to the manufacturing costs of such devices. This paper introduces a novel way of building transformer cores, namely the sub-cores, using consolidated stacks of electrical steel to reduce construction times without causing an increase in the core losses. The reduction of core losses in transformer cores has been a major area of research for many years [1-3]. The efficiency of transformer cores throughout the years is a combination of two main factors; production of superior magnetic materials and optimised transformer core geometries. From the solid, non-silicon, iron cores of the late 1880's to the conventional butt-lap and mitred core designs of recent times, the no-load losses of transformer cores have been reduced by approximately 70%. This reduction has been achieved due to the better understanding of the flux behaviour inside the core, and the better utilization of the properties of modern electrical steels.
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