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Many think they are essentially just chunks of iron wrapped with wire. If you thought that, then you'd be wrong.
Okay, yes, it's still a block of iron with wire wound around it, but there are a huge number of factors which go into building a transformer which make it such a dynamic essential to a wide variety of applications. The design of a transformer can be hugely complicated considering the amount of power it has to transform, the properties of the power going in and coming out, environmental factors, efficiency issues, sizing requirements, availability of materials and, subsequently, the amount all this will cost before the first turn of wire makes it around a steel core.
There are two major factors to the cost of a transformer: what you pay for it, and the cost to run it. A well-built, efficient unit with low losses will keep the running cost of the transformer to a minimum and can be defined by its loss rating. But to build a high efficiency transformer, you need the best quality materials which will come at a premium – so in keeping running costs down, you must be prepared to make sacrifices to your initial outlay. Or do you...?
One of the major parts of the manufacturing process of transformers, core stacking is a very delicate procedure, particularly for larger transformers. It involves a lot of precise and fine operations which used to be possible only for very skilled workers to execute. The stack must be uniform on all sides, built flush, and fit precisely through the windings. Little deviations will cause vibrations, noise, heat and – ultimately – losses. Urgent improvements were required here.
To support a continued increase in business, particularly the demand for high efficiency transformers, Electro-wind has invested in state-of-the-art machinery at its factory in Stoke-on-Trent. This investment, made earlier in 2017, is now fully operational with the commission of a magnetic steel lamination stacking machine.
The new unit saves labour by rapidly and accurately building up steel laminations, inserting E/I or U/I core plates into a bobbin at high speed, with excellent performance. The tooling works with a variety of thicknesses and can be set for an array of single- and three-phase laminations. This provides the benefits of rapid production, maintaining an accurate count on every project, a simplified operating process, and outstanding product quality.
With a packing speed of up to one hundred laminations per minute, it can complete a lamination pack of fifty millimetres in about two minutes – a job which would take a human operator in excess of ten minutes to finish. Additionally, even an experienced operative stacking a transformer by hand would be prone to making occasional errors in stacking, would have to spend additional time hammering the laminations into a flat plane, and would have to take the time to remove and refit any laminations which were bent or distorted in the process.
This new machine delivers superior speed and accuracy, utilising easily interchangeable dies, blocks and assembly tools. Not only does this increase the speed which transformers are built, but it also minimises waste material. The unit even comes with air-operated extraction which aids removal of the bobbin when the packing is finished to assist the operator in quickly setting up the next job. The finished product also benefits from advanced levels of quality, thanks to the precision fit afforded by the new machine.
Because the new machine consistently stacks magnetic steel laminations singly, uniformly and without errors, the completed unit will run more efficiently, reducing losses and making your transformer run cleaner and greener with considerably fewer losses and lower running costs.
The combination of speed, accuracy and reduced waste allows Electro-wind to become even more competitive in the growing construction and electrical sectors. This investment continues Electro-wind’s commitment to driving up quality and reducing manufacturing expenditure. These benefits are passed on to the customer in the form of better quality and more competitively priced products. Lead times are also reduced following the resulting improved productivity. You won’t have to compromise your initial outlay to improve transformer efficiency. So not exactly just a chunk of iron with wire wrapped around it!
For detailed information on Electro-wind’s range of energy efficient transformers, as well as its reactors, chokes, rectification units, and site electrical equipment, please get in touch on 01782 776321 or by emailing email@example.com. Alternatively, you can find a wealth of information on www.electro-wind.co.uk. All products can be designed to best suit your project requirements, and there is a range of off-the-shelf units available directly.
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