Transformer – How It’s Made

Electrical Power Transformer we can see everywhere in our neighboring street. It has an important role in our daily life. Our home equipment can operate with the high voltage that we generate in Power Station. This is the only equipment in a substation that step down the voltage level from high voltage. In this post, we will learn, “Transformer – How It’s Made?”

Transformer- How It’s Made:

Generally, a transformer manufacturer starts to make a transformer by two materials. First one is paper and it always coated by the epoxy glue. Worker tape this paper with a wooden block. The second material is 3mm thickness aluminum strip. These metal strips withstand the heat and high voltage current produces. Then the worker secures both materials with the same wooden block and rotated it. By this rotation paper and metal strip become together.

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After that, an aluminum Bus Bar called the low voltage lead and it sends the low voltage current out of the transformer. Then the worker folds the leads and sends it to another rotating block for further wrapping. The insulation paper has epoxy glue on its both side and it is essential for next wrapping. Because this epoxy glue will melt during the baking section and make a bond with several components.

On the new block a worker tapes on more epoxy glue insulating paper. Then they tape epoxy coated copper wire. Worker roll on a layer of copper wire covering the insulating paper. They repeat the same process again to forming the second layer of copper wire. After that worker joint the high voltage leads with the copper wire by soldering. Then he rolls another layer of copper wire.

After that worker attached what’s called leads wire out. The wire that will protrude from the power transformer cylinder and the vinyl coated wires that will two different voltages out of the transformer. Till now they are making the coil for a transformer. It also has other important parts called core. Worker uses electrical steel to make its core. After that, they secure the core and coil by metal strapping. This strapping will keep these two parts together in the transformer tank.

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After strapping worker sends complete assembly to the oven. Oven temperatures maintain 135-degree calculus. It will bake for the next eight hour for removing any trace of humidity and improve the insulation. This baking also fused the epoxy glue with insulation paper, aluminum strips and the copper wire. Then complete assembly goes into the transformer tank. You can say it is the outer shell of a transformer.

Then worker attached the rubber gasket with the round edge of the tank by a hammer. Because this tank needs to be completely water resistant. Then the bolt the grounding wire with the tank. After that, they insert three thermoplastic bushings. Then they connect the low voltage leads with the thermo plastic bushings. After that, they bolt the bushings to the tank. They also add a transformer oil filled guide with the side of the tank. Then they position automated transformer oil filled machine at the top of the tank. This machine will create vacuum pressure to remove air during oil filling.

This oil is used for transformer insulating and cooling purpose. They also attached an internal fault detector to alert the maintenance crews if there is any short circuit. Then worker inserts a leads wire through the incoming thermo plastic bushings and secure it in place. Then they attached the high voltage cable connector with it. After that, they bolt the tank cover. Now before the transformer goes to service it needs to pass the testing department. They test each unit of the transformer by simulation with actual power. When it passes then it’s ready to hang with your nearby utility pole.

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