Transformer Core Building and Assembly - Case Study for Industrial Engineers

ABB Power Transformers -- A guide to manufacturing
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https://www.youtube.com/watch?v=Flu0Tddik6o
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2020

https://www.electricalindia.in/solar-transformers/  - Magazine

https://www.hitachiabb-powergrids.com/au/en/offering/product-and-system/transformers/smart-transformers

https://www.globenewswire.com/news-release/2020/04/02/2010936/0/en/Global-Power-Transformers-Industry.html

https://www.gbeonline.com/en/transformers-for-railway-application/

https://www.transformer-technology.com/es/  Magazine

2019

Murata new transformers for high power high frequency applications.

https://www.murata.com/en-eu/products/info/power/magnetics/2019/0926

2018

CONTROLS UPGRADE BOOSTS WINDING MACHINE PRODUCTIVITY 40%

One recent machine retrofit of machine and motion controls increased productivity 40% since project completion, according to the plant maintenance manager, with an increase in quality and less scrap and a return on investment in six months.

The average running speed prior to the upgrade was 350 feet per minute (fpm). After the upgrade, the customer regularly runs at 600 fpm, and the machine is can run up to 850 fpm on a 1-in. strip, an impressive response for a traverse winder.

https://electronicdrives.com/home/controls-upgrade-boosts-machine-productivity-40/

2015  

Patent

Transformer insulation paper clipping mechanism

Abstract

The invention provides a transformer insulation paper clipping mechanism. The transformer insulation paper clipping mechanism comprises a rack, a feeding support, a clipping mechanism and a conveying mechanism are sequentially arranged on the rack, the clipping mechanism comprises a guide plate and pneumatic shearing machines arranged on the two sides of the guide plate, each pneumatic shearing machine comprises a plurality of sets of blades, the blades are arranged on the rack through a cutter rest, a blade air cylinder arranged on the rack drives the blades to rotate to perform the clipping motion, and a plurality of opening grooves matched with the blades are formed in the two sides of the guide plate. By means of the transformer insulation paper clipping mechanism, transformer insulation paper is pressed in through the feeding support; even notches are formed in the lateral sides of the insulation paper through the clipping mechanism under guiding of the guide plate, and conveying and outputting are carried out through the conveying mechanism. By means of the transformer insulation paper clipping mechanism, the efficiency and the accuracy of the transformer insulation paper clipping operation can be improved, uneven notch depths caused by manual clipping cannot be caused, and the product performance can be guaranteed.

https://patents.google.com/patent/CN104526739A/en

Transformer Manufacturing Process - Exercise for Industrial Engineers

Understand the application of these patents in transformer manufacturing process.

US2260398A
United States
Inventor. Otho M Otte
1939-05-25: Application filed by Otho M Otte
1941-10-28: Publication of US2260398A
Transformer
H01F27/25 Magnetic cores made from strips or ribbons
https://patents.google.com/patent/US2260398


US2671951A
United States
1949-10-03
Application filed by Jefferson Electric Co
Transformer core and method of making same
https://patents.google.com/patent/US2671951A/en

US2892169A
United States
InventorWilliam L TeagueJames H McwhirterCurrent Assignee CBS Corp
1954-08-20: Application filed by Westinghouse Electric Corp
1959-06-23: Publication of US2892169A

Transformer core structures

 H01F27/245 Magnetic cores made from sheets, e.g. grain-oriented
https://patents.google.com/patent/US2892169A/en


US2947961A
United States
Inventor. Wallace W Wahlgren
Current Assignee.  ELECTRO ENGINEERING WORKS
1959-01-07: Application filed by ELECTRO ENGINEERING WORKS
1960-08-02: Publication of US2947961A

Transformer or reactor core structure

H01F27/245 Magnetic cores made from sheets, e.g. grain-oriented
https://patents.google.com/patent/US2947961

US4520556A
United States
 General Electric Co
1985-06-04
Application granted

Methods for assembling a transformer core

Abstract
Power Transformer cores are assembled by inserting a plurality of lamination inserts between the upper yoke laminations and the leg laminations in the transformer core assembly process. The arrangement allows the upper yoke to be readily removed for inserting the transformer windings over the core legs. The upper yoke is then reassembled with the inserts reinserted to complete the transformer core.
https://patents.google.com/patent/US4520556A/en


US20160005536A1
United States
2014-02-07
Application filed by ABB Technology AG

Method for manufacturing a stacked triangular core transformer

Abstract
A method for manufacturing a stacked triangular core transformer includes assembling a triangular core by positioning of two halves of one leg on an assembly stand in the horizontal position; securing the positioned halves; positioning an outer clamping beam underneath two leg halves at the one end of the leg halves; assembling a yoke segment at the one end of two halves of the core leg; and forming a first clamp of the frame. The method continues by forming a second clamp of the frame at the other end of the two halves of the core leg by repeating the above positioning, assembling and forming steps; tightening the clamps together by securing means; rotating a single core frame into vertical position and releasing securing bar of the assembly stand; assembling two additional single core frames by repeating the above steps; positioning the frames in abutting position, and tightening them together.
https://patents.google.com/patent/US20160005536A1/en


US20130088314A1
United States
Application filed by Hydro Quebec Corp
2013-04-11
Publication of US20130088314A1
2015-12-08
Publication of US9208933B2

Annealing of Transformer Core

Method of stress-relief annealing a magnetic core containing amorphous material

Abstract

A method of stress-relief annealing a magnetic core constructed of magnetic, metallic strip material, with at least a portion of the strip material being amorphous, wherein the strip material has major plane surfaces which define first exposed surfaces of the magnetic core, and lateral edges which collectively define second exposed surfaces of the magnetic core. The method includes the step of thermally insulating the first exposed surfaces of the magnetic core, and the step of heating the magnetic core via the second exposed surfaces.

US4832763A

United States

 

InventorGary C. RauchRichard E. Kothmann  Current Assignee ABB Inc USA

1985-10-15: Application filed by Westinghouse Electric Corp

1985-10-15

Assigned to WESTINGHOUSE ELECTRIC CORPORATION, WESTINGHOUSE BLDG., GATEWAY CENTER PITTSBURGH, PA 15222 A CORP OF PA

1989-05-23 Publication of US4832763A

1990-06-07 Assigned to ABB POWER T&D COMPANY, INC., A DE CORP.

2006-05-23 Anticipated expiration

Status Expired - Fee Related

https://patents.google.com/patent/US4832763A/en

Amorphous core annealing method

Abstract

There is provided an amorphous core annealing method in which the annealing temperature distribution within an iron core is regulated so that deterioration in the magnetic properties, which is caused by unevenness of the annealing temperature within the iron core, can be suppressed, and the annealing time can be shortened. In order to regulate the annealing temperature distribution within the amorphous core at the annealing time, a heater 2a functioning as a heat source is held between laminated thin-film amorphous materials of an iron core 1a, and annealing is performed. By uniformly regulating the annealing conditions within the iron core 1a, deterioration in the magnetic properties, which is caused by unevenness of annealing, can be suppressed to a minimum. Also, an iron core of a special specification, for example, an iron core having a low core loss, or an iron core having a high magnetroresistance, can be manufactured by purposely using different annealing conditions within the iron core 1a. Further, the annealing time can be shortened by increasing the absolute quantity of heat transferred to the iron core per unit time. The iron core may be heated and annealed from the lamination surface, or may be annealed by being extended in the direction perpendicular to the lamination surface so as to form a plurality of steps.

EP2533259A1

European Patent Office

 

2010-02-04: Priority to JP2010023224A

2011-01-18: Application filed by Hitachi Industrial Equipment Systems Co Ltd

2012-12-12: Publication of EP2533259A1

2016-07-13: Publication of EP2533259A4

Status: Withdrawn

https://patents.google.com/patent/EP2533259A1/en

Electrical Transformer Assembly

Abstract
A support frame for an electrical transformer assembly, comprising two loop-shaped parts, each loop-shaped part having a plurality of limbs, each limb having a peripheral recessed portion in which a primary electrical coil is mountable, and at least one secondary coil is mountable in piggyback on the primary electrical coil, one limb of each loop-shaped part having a straight section. The frame also includes an adjustable attaching means for attaching one of the loop-shaped parts with respect to the other loop-shaped part and adjusting a distance therebetween, so that only the straight sections are adjacent and form a central leg, the central leg being for receiving a magnetic core distinct from the attaching means. The frame provides a means and a method to efficiently secure adjacent windings in a circular core transformer kernel.
https://patents.google.com/patent/US20130088314A1/en



https://www.electronics-tutorials.ws/transformer/transformer-construction.html

Core Construction, Design
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https://www.youtube.com/watch?v=yeXCIR759SA
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Projects of Students

Design of Transformer under Short Circuit Conditions
VJTI, 2008-2009
https://fdocuments.in/document/project-report-final-year.html


The Magnetic Circuit (Core)


ETS specializes in the manufacture and supply of step-lap cut cores & stacked cores. The iron cores are manufactured with cold rolled grain oriented electrical sheet steel having thicknesses of 0.30mm, 0.37mm and 0.23mm.
https://www.emiratestransformer.com/cat_section_59/core-assembly.html


Distribution Transformer Project Feasibility Report
MSME Development Institute Kanpur - 2010
https://www.dcmsme.gov.in/reports/electronic/DISTRIBUTIONTRANSFORMER.pdf

IEEMA Material on Transformer

Standardizing Transformer Specification
http://ieema.org/wp-content/uploads/2015/04/TManual-Chapter-01.pdf

http://ieema.org/wp-content/uploads/2015/04/TManual-Chapter-05.pdf

Machinery Used in Transformer Manufacturing

1998

Electromagnetic flat-faced robot gripper for handling multiple industrial transformer core lamination plates
Abstract:
In the industrial transformer core assembly process, significant productivity gains can be achieved by utilizing a robotic gripper that is able to handle, and accurately position, multiple transformer laminations during each pick-and-place cycle. This paper reports on the development of a novel electromagnetic lifter for such applications. The lifter has the unique capability to selectively pick a given number of laminations at a time (the usual requirement is three) from a stack. Experiments were c conducted on a prototype electromagnet.
Published in: IEEE Transactions on Magnetics ( Volume: 34 , Issue: 3 , May 1998 )
B. Postma ; T. Vinay ; T. Kangsanant ; A. Harvey
https://ieeexplore.ieee.org/abstract/document/668070

Transformer Core Stacking Table

SHANDONGYINGBO ELECTRIC POWER EQUIPMENT CO.LTD
 Transformer Core Stacking Table is designed according to German technology and demands of many international transformer manufacturer giants. It is suitable for stacking cores with 3 and 5 limbs.

This Core Stacking Fixture is windly accepted by ABB, SIEMENS, AREVA etc.

There is a series of 30ton, 50ton, 80ton, 120ton, 150ton and 250ton.
Established in 2004 , SHANDONGYINGBO ELECTRIC POWER EQUIPMENT CO.LTD has made a name for itself in the list of top suppliers of Industrial Machinery & Parts, Industrial Machinery & Parts in China.
https://www.tradeindia.com/fp900160/Transformer-Core-Stacking-Table.html

More Patents

http://www.freepatentsonline.com/2892169.html

http://www.freepatentsonline.com/3325886.html

http://www.freepatentsonline.com/3223955.html

https://patents.google.com/patent/CN202076079U/en

https://patents.google.com/patent/CN202710709U/en



More information - Winding

https://www.zippia.com/winding-machine-operator-jobs/skills/

https://ludens.cl/Electron/trafos/trafos.html

https://study.com/articles/Coil_Winder_Machine_Operator_Employment_Information_and_Requirements_for_Becoming_a_Coil_Winder_Machine_Operator.html

https://en.wikipedia.org/wiki/Coil_winding_technology

https://www.sagareng.com/transformer-coil-winding-machines.html

https://www.spxtransformersolutions.com/power-transformers/manufacturing/core-and-coil/

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https://www.youtube.com/watch?v=O0Jjs-6ydH4
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Transformer Core Annealing Furnace

https://www.vacfurnace.com/equipment-for-wound-cores-annealing-in-transformer-field/

https://www.precisioncontrols.in/annealing-furnace.html

"Numerical model and optimization strategy for the annealing process of 3D coil cores"

Highlights

• Digital twin model gives a near real-time prediction.

•3D features of heat transfer inside annealing furnace are reserved.

•Typical error of annealing model for 3D coil cores is less than 2.5%.

•Optimization strategy reduces 15% of annealing time.

Authors: Ruifeng Dou,  Haoxiang Zhao, Pengfei Zhao, Zhi Wen, Xianhao Li,  Liang Zhou, Rongzhao Zhang

Applied Thermal Engineering

Volume 178, September 2020, 115517

https://www.sciencedirect.com/science/article/abs/pii/S1359431120329999

Transformer Tank

DESIGN OF TRANSFORMER TANK WITH TUBES
15 Apr 2020
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https://www.youtube.com/watch?v=qcWp6J3dgzE
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Transformer Tank Fin Folding Machine

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https://www.youtube.com/watch?v=o7q30P4H-iI
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https://www.nakodasteel.in/transformer-frame-parts.html
Vadodara Gujarat

The operation process chart of segments of transformer manufacturing process is given as an exhibit.

 

SEGMENTS OF TRANSFORMER OPERATION PROCESS CHART

      CRGO Imported Sheets

           --------------------------                                                                                          

                                             |

                                             o 1. Core Cutting & Wrapping

                                              |

                                             o 2.  Core Forming

                                              |

                                             o 3.   Core annealing

                                              |

                                              o  4.   Core & Coil Assembly & CCA Frame

                                              |

                                             o   10. Drying in Drying Chamber

                                              |

                                              o 12. Coil-stack assembly placed in tank

                                              |

                                              o 14. Testing & Packing

                                              |

                                              o 15. Packing

 

 

Materials input: 8mm Copper Rod

-----------------------------------------------

                                               |

                                               |

                                               o 5. LT Strip Bare & Paper Covered

                                               

 

Materials input: 8mm Copper Rod

-----------------------------------------------

                                               |

 

                                               O 6. Intermediate drawing

                                               |

                                               O 7. Super Enamel Copper Wire

 

 

 

 

 

 

 

Insulating  Materials Paper & Press Board

-----------------------------------------------

                                               |

                                               |

                             8. Paper Slitting & Press Board Shearing

                              

                              HT & LT Bushing

------------------------------------------------12

                                                

 

                                               

 

Transformer Oil

------------------------------------------------

                                                |

                                                o 13. Centrifuging---12

 

 

                                   MS Sheet Import

------------------------------------------------

                                                |          

                                                |

                                                o9. Shearing & Fabrication of CCA Frame----4

 

                                       MS Sheet

------------------------------------------------

                                                |          

                                                |

                                                o11. Shearing & Fabrication of Tank & Accessories--12

 

 

 

  o9. Shearing & Fabrication of CCA Frame

https://www.freepatentsonline.com/5684446.html

https://www.freepatentsonline.com/y2016/0086710.html

 

Transformer manufacturing companies - Info.

https://documents.pub/document/energypac-engineering-new-corporate-presentation.html

Updating  25 August 2020
3 August 2020