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Step-Lap Core | Laser-Scribed Silicon Steel | Wind Turbines, Industrial UPS & Railway Traction Systems
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Step-Lap Core | Laser-Scribed Silicon Steel | Wind Turbines, Industrial UPS & Railway Traction Systems

Step-Lap Core - Multi-Offset Laminated Silicon Steel Assembly for Ultra-Low Vibration Energy Transfer in Wind Power Converters, Critical UPS, and Rail Electrification

The Step-Lap Core employs precision-stacked, laser-scribed grain-oriented silicon steel (0.18–0.30mm thickness, 3.2–3.8% Si) with staggered joint geometry. This patented multi-offset lamination eliminates traditional butt joints, reducing interfacial air gaps by 95% and creating a near-continuous magnetic path. Optimized for 50Hz–2kHz high-power applications, it achieves flux uniformity >99% while cutting audible noise to <35dB at 1.7T excitation.

    Common Applications

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    Renewable Energy

    Wind turbine converters: 99.2% efficiency at 3MW/690V (IEC 61400-25 compliant).
    Solar farm step-up transformers: 35-year design life at 1.2p.u. daily cycling.

    Industrial Power Protection

    Double-conversion UPS: Maintains <1% THD during 0–100% load transients.
    Data center PDU: 97.5% efficiency at 50% load with 3:1 overload capacity.

    Rail Electrification

    Traction transformers: 25kV/50Hz operation with <40dB noise (EN 50263 certified).
    Auxiliary converters: 150kW compact design for high-speed train HVAC.

    Power Transformer Field

    It can be used to manufacture power transformers of various power levels, from low-voltage small-power to high-voltage high-power transformers. Its step-lap lamination structure can reduce air gaps in the magnetic circuit, lower magnetic resistance and losses, improve transformer efficiency, and at the same time make the core structure more compact, optimize the transformer volume, and facilitate installation and transportation. 

    Electronic Transformer and Instrument Transformer Field

    It is often used in 50Hz transformers and instrument transformers in electronic equipment, which can improve electromagnetic performance and ensure the accuracy of signal transmission and measurement. For example, in the power transformers of precision instruments, it can reduce electromagnetic interference and ensure stable operation of the instruments; in current transformers and voltage transformers, it helps to accurately measure current and voltage and reduce metering errors.

    Reactor and Choke Field

    It can be used to manufacture components such as reactors and chokes. In power systems, reactors are used to limit short-circuit currents, compensate reactive power, etc. The step-lap core can reduce their operating losses and improve performance. In electronic circuits, chokes use their low magnetic leakage characteristics to stabilize current and suppress harmonics, which are commonly found in audio equipment, communication power supplies, etc., and can reduce interference and improve equipment performance.

    Motor Field

    It can be applied to motor rotors. By arranging the magnetic poles in a step-lap manner in the rotor lamination core, a smoother torque curve can be achieved, reducing vibration and noise during motor operation, and improving the stability and reliability of motor operation. It is often used in electric vehicle drive motors and other motors with high requirements for torque smoothness.

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