Training Manual

Transformer :

Date :25th Sep 2012

A transformer is a power converter that transfers electrical energy from one circuit to another through inductively coupled conductorsthe transformer's coils.

Inductor :
An inductor is a passive electronic component that stores energy in the form of a magnetic field. In its simplest form, an inductor consists of a wire loop or coil.

Core :
1).CRGO 2).CRNGO 3).Ferrite Core
CRGO : Cold rolled grain Oriented steel CRNGO : Cold rolled non grain Oriented Steel.

Toroidal Core
WINDING :
The slitted coils of CRGO are wound on semi automatic winding machine as per the dimensions. Winding should be very tight.

SPOT WELDING :
On winding the CRGO Toroidal cores to the exact size the start and finished ends
of the core are spot welded on Tig welding machine

STRESS RELIEF ANNEALING :

During the winding process of CRGO, severe stresses are induced in the gains of the raw material. Theses stresses are relieved in our annealing furnace equipped with automatic temperature controller, circulating fan and inert atmosphere. The annealing cycle (at 800C) improperly controlled to get uniform and best annealing results.

Toroidal Core

Important factors: 1.It should be very tight. Otherwise it will reject due to following reasons a) Noise b) Magnetizing current - will increase. 2.It should be as per dimensions.

Insulation:
Insulation Machine:

Transformer

Material used
Copper and Aluminium
Magnet wire or enamelled wire is a copper or aluminium wire coated with a very thin layer of insulation. - We should handle the wires carefully. Otherwise enamel coating may damaged.

CHARACTERISTICS
Tensile strength for same conductivity (lb) Weight for same conductivity (lb). Cross section for same conductivity (C.M.).

COPPER
55,000 100 100

ALUMINUM
40,000 48 160

Tensile Strength is very low in aluminum wire. So we should give very low tension in Process. Otherwise it will elongate.

Insulation Materials
Polyester tapes Tufquin. 3M Powder.

Process Steps
1.Core Insulation 2.Primary winding 3.Lead fixing/Sleeve fixing 4.Primary to Secondary Insulation 5.Secondary winding 6.Lead Fixing 7.Final Insulation 8.Potting.

Transformer:

Insulated Cores
Powder Coated Cores Insulated by Polyester Tape

Coating Thickness should be as per specification. Ferrite Cores

Core Should not have any Burrs. % of Over lap should be very accurate

Insulation
Insulation should be as per Specification. If Insulation is weak, then Transformer may fail due to the following reasons 1).Short circuit 2).High Voltage fail. It should withstand the pressure of primary winding copper. - So Perfect insulation required. Material rejection/Scrap should be avoided 100%. - More material cost - Should reduce the rejections. Our is ISO 14001 company. Insulation : Stage 1 Core Insulation Stage 2 Winding Winding Insulation Stage 3 Primary Secondary Insulation. Stage 4 - Final Insulation.

Winding Process
Winding Machine :

Magazines and Core Rotation Unit

Magazines

Magazines

Bed Rollers

Core

Magazine Rollers

Drive shaft

Winding Instructions:
Check the Magazine setting, Guide Pulley,Guide pinThere should not be any burrs.
Burrs: It will remove the enamel coating of copper. This leads to short circuit of windings Result : Transformer fail. Cross winding: Winding Should be very straight. Cross winding should be arrested 100%. Impact: There is more Stress on cross winding. This will leads to enamel weak at cross wounded spot. After some time we will face short circuit at the cross wounded spot.

Scratch : Enamel coating is removed due to process/Handling. We should take care while processing or Handling. Handling should be perfect.

5S
Before
After

5S

Safety Steps in Training The teaching process can be broken down into five steps--Prepare, Tell, Show, Do, and Review. A closer look at each of these steps will assist the employer or trainer in understanding this process. Discussion about this five-step process is drawn from publications on training by Dr. Bernie Erven of The Ohio State University. Prepare--The first step in this process is to prepare the learner. The trainer should put the learner at ease and explain why the skill to be learned is important. Explain any hazards or problems that may be involved and how to deal with them. Answer any questions that the learner may have about the task. Tell--Explain the task thoroughly. Break it down into key parts or steps. Most employees will find that learning several smaller tasks and putting those together is easier than trying to learn one large skill all at once. Show--Demonstrate for the employee exactly how the task or skill is to be performed. Involve the employee by asking questions and getting feedback. Have the learner explain the process or skill back to the trainer. Do--The learner now has the opportunity to perform the task. The trainer needs to help the learner develop confidence by at first carefully monitoring the learner, then allowing him/her to work without supervision. The employee needs to make sure that the employee performs each step correctly and avoids developing any bad habits. Review--Provide honest feedback to the learner in terms of encouragement, constructive criticism and additional comments. This is a great opportunity to praise the employee or correct his/her progress.

Crimping - Insulation Crimp The insulation crimp section holds the insulation in place applying pressure on all sides. A loose crimp does not ensure that the wire is held securely with the terminal, while a crimp too tight may pierce the insulation.

Crimping - Lock Tangs Lock tangs simplify the terminal/connector assembly by locking the terminal into the connector. The opening angle varies with terminal and connector design, and may range from 2x to 10x material thickness.

Crimping - Loose Strands All stands must be collected in the wire crimp section.

Crimping - Striplength
Correct striplength is determined by terminal design. Markings on the terminal indicate exact wire end location. Typically, the stands must be visable after the wire crimp area by about one wire diameter.

Crimping - Terminal Damage

The crimp tool may damage the terminal due to improper allignment of the terminal in the press.