What equipment do I need to produce transformers?
Equipment required for the production of high-frequency transformers: CNC, lagging machine, vacuum impregnation equipment, dispensing machine, oven, tin pot, testing instruments are used for full foot machines, including withstand voltage tester (ARC), 500k comprehensive test instrument, interlayer test instrument, transformer tester and various tools. Generally speaking, if you want to produce transformers, you must need technical support.
What conditions and materials are required to produce transformers?
First of all, we should understand the classification and main uses of transformers: single-phase transformers and three-phase transformers are classified according to the number of phases. Single-phase is commonly used for isolation, voltage level changes, and impedance changes in AC circuits. Three-phase transformers are typically used for changes in voltage and transmitted energy in transmission and distribution systems.
Depending on the application: instrument transformers (often used in electrical measurement and protection devices): electric furnace transformers (often used in smelting, heating and processing equipment power supplies): autotransformers (often used in laboratories or industrial voltage regulation).
According to the core structure: shell core (often used in small transformers, high-current special transformers); Core-type core (commonly used in large and medium-sized transformers and high-voltage power transformers; Type C core (transformers commonly used in electronics). According to the cooling method: oil-immersed (large and medium-sized transformers); Air cooling (forced oil circulation air cooling for large transformers); Self-cooling (air cooling of small and medium-sized transformers); Drying (high safety and fire protection requirements) Transformer structure: The structure of a transformer varies depending on the application. Taking oil-immersed transformers as an example, high-power transformers have complex structures, and most power transformers are oil-immersed, and oil-immersed transformers are composed of windings and iron cores. In order to solve the problems of heat dissipation, insulation, sealing, safety, etc., fuel tanks and insulating sleeves are also needed. Oil conservators, cooling devices, pressure relief valves, safety air ducts, thermometers, gas relays and other accessories.
Classification of high-frequency transformers.
Open transformers, potted transformers, and sealed transformers are classified according to moisture-proof methods.
Classified by cooling method: dry-type (self-cooled) transformer, oil-immersed (self-cooled) transformer, fluoride (evaporative cooling) transformer.
Classified by use: power transformer, voltage regulating transformer, audio transformer, intermediate frequency transformer, high-frequency transformer, pulse transformer.
Single-phase transformers, three-phase transformers, and multi-phase transformers are classified according to the number of phases of the power supply.
Classified according to the structure of iron core or coil: core transformer (ferrule), C shell transformer (insert core), C core, ferrite core), toroidal transformer, metal foil transformer.
What are the precautions for each process of producing high-frequency transformers?
1.Grinding air gap line report.
This kind of wire is best wound around the main winding with a skeleton. If you bypass shielding and secondary, it's easy to make mistakes. After all, it is not a transformer that grinds the core, and it can also be saved. As for how to confirm, after the winding report, you can test the laps with a lap tester. Of course, the test conditions provide a range.
2.Paint precautions.
When soaking paint, the insulating paint can not meet the pins, the vacuum does not bubble, the drying does not drip oil, and the tip of the angle must not be drilled time, after all, the size of each product, several winding retaining walls are not the same, there is no unified answer. The density of each company is different, for example, our density requirement is 092-0.93.The first thing to do is to figure out the impregnation effect that will meet your requirements.
3.Precautions for winding.
When winding, there can be no short circuit between the main winding and the secondary winding, no short circuit between the shield, no oil, and no dust. The shielding is tested with a high-voltage capacitor discharge. It is best to test with 1000VDC. If there is no problem, it can be touched with your hands. Of course, if there is a high voltage testing machine, it is better to test with 2500VDC. For multi-layer windings, such as double-layer windings, the "double flying wire" jumper method should be used. For multi-layer windings, such as four-layer windings, the "well" type bridging method should be adopted.
4.Precautions for press-fitting.
When press-fitting, it is necessary to ensure that the air gap is uniform, not too large or too small, to ensure that the transformer is beautiful in appearance, and the press-fitting must meet the standard requirements.
5.Precautions for general inspection and factory test.
Finally, when inspecting the transformer, you should be careful, don't be careless, and solve it as much as possible for some small problems, so as not to let it affect the quality of the product. Be sure to test before leaving the factory, such as withstand voltage, insulation resistance, etc., don't wait until the factory finds the problem, it will be very troublesome to deal with at that time.
The above are the precautions for the production of high-frequency transformers. Of course, this is only part of the story, and there are many details that need to be paid attention to in the production process.