Manufacturing of transformers, Physics

Before manufacturing of transformers we must know the important parts of transformer which need to be manufactured. Following are the main parts of transformers.

(a)          Former or bobbin

(b)         Winding wire or coil

(c)           Laminated iron core

(d)         Shielding and mounting assembly

(a)          Former or bobbin: Bobbin is the part of transformer on which the coil is wound. It is also known as coil former. It is made of impregnated paper materials laminated materials, thermosetting and thermo-plastic materials.

(b)         Winding Wires: On the bobbin, a low resistivity wire is wound into multi-turn with sufficient insulation to separate the turns. The wires are coated with the suitable quality of varnish. The size of the coil depends upon the current which is to be carried by wires.

(c)           Core: The core material should have low hysteresis constant to minimize the hysteresis losses in the core. Silicon steel is the perfect core material. This core is laminated to reduce eddy current losses.

(d)         Shield: Shielding is used to suppress electromagnetic interference from or to the inductor. This is done using foil.


In the process of manufacturing a transformer first of all winding of the coil over the bobbin is to be done. Winding of the coil is done by a coil winding machine. This coil winding machine either could be hand operated or it could be driven by a fractional horse power motor. A counter is provided on the winding machine which counts the number of turns wound. To start winding, first the size of the coil former and winding wire required is taken. On the surface of bobbin, a coil former should be checked first to test its smoothness so that it may not damage the insulation of the wire which is to be wound on it. After that, the cross-sectional area, length etc. Of the following are checked for it's uniformly. Then lamination, dimension, etc. Of the laminations of the core should also be checked. Set the counter of the winding machine to zero. Set the machine for required SWG wire. Set the wire in the proper place in the machine. Tighten the wire so that it will attain proper tension. Keep a layer of the impregnated paper on the surface of the bobbin, take the end of the wire and pass it through the opening in the bobbin. Now start rotation the handle of the winding machine uniformly. When entire length of the bobbin is covered, then the direction of rotation of the handle of winding machine is reversed. Wind similarly for the required number of turns. After complete winding of the inner coil of the transformer, cover it with some insulating material such as impregnated paper. Then the outer pin is wound on the bobbin in same manner in which inner coil in wound. After winding the two coils, they are covered with some insulating material. After insulating, the cover is inserted into bobbin. Then fix the terminal plate on the transformers on which terminal wire is soldered. Then the transformer is impregnated. After impregnation it is ready for testing and use thereafter.

Posted Date: 7/9/2012 7:02:35 AM | Location : United States

Related Discussions:- Manufacturing of transformers, Assignment Help, Ask Question on Manufacturing of transformers, Get Answer, Expert's Help, Manufacturing of transformers Discussions

Write discussion on Manufacturing of transformers
Your posts are moderated
Related Questions
Q. Explain what do you understand by the terms potential well and potential barrier. How does a particle with energy lesser than the barrier height tunnels through its quantum mech

Identify the action reaction pairs in the following situations: a. Snowball hits a girl in the back.  Snowball pushes girl's back; girl's back pushes on snowball. b. A base

The experimental set-up for producing Newton's ring is shown in fig. (A). A plane-convex lenses L of large radius of curvature with its convexities is placed on a plane glass plate


A sprinter runs 100.0 m. If he travels at constant acceleration of 1.95 m/s2 for the first 6.00 s, and then at constant velocity for the remaining time, what was his average veloci

sketch the setup abd show the angulare distace between successive dark bands is----------

High resistive materials: The materials which have their resistivity 10 -8 to 10 -6 ohm-m come under this category. These materials are used for making resistance elements fo

Question 1. Discuss the physical characteristics of an X-ray beam. Write a note on factors influencing the quality and intensity of the X-ray beam 2. Explain the constructio

Q. What takes place when you travel across the dateline? Answer:- If westbound the day modify to the next day. If eastbound the day is the day prior to. Appears strange bu