Product Overview
Traditional engineering standards only recommend hardened copper for equipment exposed to intense electrodynamic impact. Our proprietary award-winning alloy aluminum continuous transposed conductor (CTC) breaks this limitation.We successfully industrialized this innovative design, enabling aluminum CTC to achieve mechanical performance equivalent to copper transposed wires.
Enameled Aluminum CTC is a custom-engineered winding conductor developed for high-voltage transformers and power reactors. It adopts high-purity electrical grade aluminum flat strands as the base material, each strand coated with high-temperature resistant enamel insulation, then formed via precision continuous transposition process.
Compared with traditional copper transposed conductors, this aluminum solution delivers equivalent electrical performance while significantly reducing equipment weight and overall manufacturing cost. It is fully aligned with the first-class energy efficiency standard of power transformers, and widely applied to windings of 110kV and below power transmission and distribution equipment to support low-carbon operation of new power systems.
Core Technical Advantages
With dedicated transposition layout technology, each aluminum strand occupies all positions across the bundle cross-section evenly, greatly reducing winding circulating current loss and eddy current loss. The design precisely matches the first-class energy efficiency index of transformers, helping cut equipment operation energy consumption and meet low-carbon targets of power grids.
The high-compactness enamel coating process covers B/F/H thermal classes, with excellent breakdown voltage performance. It features outstanding thermal aging resistance and short-circuit thermal shock resistance. No enamel cracking or insulation attenuation occurs under long-term high-voltage operation, ensuring full life-cycle safety of transformer windings.
Made of ≥99.7% high-purity electrical grade aluminum with uniform and stable conductivity. Optimized annealing process improves tensile strength and bending resistance of the conductor. Under instantaneous electrodynamic force and thermal impact caused by short-circuit heavy current, the strands are not easy to twist and deform, guaranteeing strong structural stability of the winding.
Compared with copper transposed conductors of the same specification, aluminum conductors effectively reduce the overall weight of transformers and control raw material and manufacturing costs. It fits the lightweight and economical manufacturing trend of green power equipment, and helps customers optimize the full life cycle cost of projects.
Field-Proven Performance: 110kV First-Class Energy Efficiency Transformer Short-Circuit Withstand Test
Our custom enameled aluminum CTC is selected as the core winding component for the self-developed 110kV first-class energy efficiency aluminum conductor transformer of Changzhou XD Transformer Co., Ltd., and has successfully passed the authoritative short-circuit withstand test with all performance indicators fully compliant.
The short-circuit withstand test is recognized as the most stringent reliability assessment for power transformers. The huge electrodynamic force and instantaneous thermal impact at the moment of short circuit can easily cause winding deformation, insulation damage and structural failure, which directly examines the mechanical strength, enamel insulation performance, transposition structure stability and heat dissipation capacity of the transposed conductor.
Throughout the whole test, the winding equipped with our enameled aluminum CTC showed no structural deformation and no insulation cracking, with electrical parameter fluctuation fully meeting design requirements, and successfully passed the extreme working condition assessment.
Full-Process Quality Assurance
From structural design, in-house bare aluminum wire production, insulation coating, precision transposition to ex-factory full inspection, we implement strict quality control for the whole production chain, which is fully adapted to the working condition requirements of 110kV high-voltage main transformers.
- In-house bare aluminum wire production with 100% eddy current non-destructive flaw detection
- Closed-loop controlled enamel curing line with online pinhole and thickness inspection
- Precision continuous transposition with pitch tolerance controlled within ±0.1mm
- Full offline testing for each batch: DC resistance, insulation breakdown voltage, dimensional accuracy and mechanical strength verification
- Full batch traceability of all production parameters
Main Application Scenarios
- 110kV and below oil-immersed / dry-type power transformers
- First-class energy efficiency distribution transformers
- Grid shunt and series filter reactors
- New energy grid-connected converter transformers
- Low-carbon green power transmission and distribution equipment
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