Transformers fabrication and the usage of these electronic devices has changed in the past years

The importance of the transformers fabrication

Transformers fabrication, many transformer components and transformer technology have constantly progressed in the past years. Due to technological innovations in the electronics manufacturing sector, lots of electronics appliances were developed that work without any transformer. However, many electronics still depend on a transformer which supports the conversion of Alternating Current to Direct Current or DC to AC. Transformer devices can also convert DCs voltage or current and change the frequency of AC supply. Generally speaking, a transformer is an electrical device which transfers energy from one circuit to another based on magnetic coupling. A transformer consists either of one tapped winding or several coupled windings as well as a magnetic core. A transformer is known in the electronics sector as a quite simple electrical device. However, transformers are used in a great variety of applications, either in industrial applications or in consumer electronics. Transformers are, for example, essential for the high voltage power transmission. Audio frequency transformers were often used in the telephone industry or for stage microphones. In these microphones, transformers are very small and connect a microphone to audio amplifiers and radio receivers. Transformers are also used in video technology and can be found in many recorders for VHS or Beta tapes. In the industrial and manufacturing sector, powerful transformers are crucial when it comes to long distance electronic power transmission. Especially in the steelmaking industry, power transformers are supplied by manufacturers and wholesalers. Rotary and sliding transformers support manufacturing companies in the effective and quick transmission of signals or power. In many production

sites, electronics components, which are quite similar to transformers, are used for the measurement of position, distance or angle. As transformers manufacturing, wholesale and distribution has become a global business activity, international standards play a vital role in this field. The introduction and the amendment of standards, valid for participating companies of this industry sector, define rules, quality characteristics and uniform measures. Assuming that producers of transformers or single transformer components have the same technological know-how and resources, a subcontractor in India or Germany might manufacture a transformer component which a US factory implements in its products. As many electronics, both in the industrial as well as in the end consumer sector, have planned obsolescence and follow-up models are developed and marketed quickly, a new global challenge emerged: There has been a steady increase of E-waste, which is responded to by the introduction of disposal, dismantling and recycling systems and services.

Manufacturing Process

Winding

Both High Voltage (HV) and Low Voltage (LV) windings are done using Coil Winding Machines. The Copper or Aluminium strips/wires used in winding are meticulously selected for its quality to give the best output.

The Copper or Aluminium strips/wires are paper covered and acts as insulators. This helps to increase short-circuit strength, thermal strength and higher efficiency.

Core

The Cold Rolled Grain Oriented (CRGO) laminations used in transformers are of high quality. They are in the form of thin sheets and they are cut as per the design varying for different capacities of transformers.

Highly skilled people assemble the laminations on a core channel to form CORE. These are perfectly assembled without any gaps to avoid energy loss.

Assembly

The wound coils are placed carefully in the assembled core. Insulations are given wherever required using materials like press board. The CORE bolt and tie rods are fixed in position. The Primary and Secondary windings are connected as per the requirement.

The complete assembly is kept in the Hot Air Chamber and a high temperature is maintained to prevent any moisture in the CORE coil assembly.

Tanking & Painting

The tank is fabricated with high quality MS plates. The assembled job is placed carefully inside the tank. The bushings, tap switch drives and lug sockets are fitted on the tank. The oil is filled and the cover is placed on the tank frame and bolted. 2 coats of anticorrosive paint and 2 coats of enamel paint are painted on the outside of the tank. The inner portion of the tank is painted with varnish.

Testing

The transformers are individually tested and the following routines tests are conducted in our lab:

No Load Loss, Full Load Loss, Double Frequency Double Voltage Test, High Voltage Test, Insulation Test, Measurement of Resistance, Heat Run Test, Pressure Test on Tank, Break Down Voltage - BDV and Acidity Test on Transformer Oil.