MAKING A SOLID ( STEEL ) INVESTMENT
ELECTRICAL & ELECTRONICS
Transformers are among the most basic electrical devices in a power distribution system . Essentially , it ' s a chunk 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 our range of energy efficient transformers , as well as our reactors , chokes , rectification units , and site electrical equipment , please get in touch on 01782 776321 or by emailing sales @ electro-wind . co . uk . Alternatively , you can find a wealth of information on our website : www . electro-wind . co . uk - all our products can be designed to best suit your project requirements , and we have a range of offthe-shelf units available directly .
Electro-wind is committed to deliver the highest quality goods , to meet and exceed customer expectations , and to reduce the environmental impact of our products and solutions . Through closely working with our clients ’ design requirements , we can achieve short lead times , produce energy efficient products and , perhaps most importantly , create a sustainable environment for years to come .
102 PECM Issue 34