High-Efficiency Production Process of Special Transformers: Prosesong Paghimo, Kontrol sa Kalidad, ug Pagmarka sa Performance

Isa ka pipila ka special nga transformer manufacturing enterprise, nga nagproduktu hin mga espesyal nga transformers sama an split-phase-shifting rectifier transformers, rectifier transformers para han electrolysis, ug transformers para han submerged arc furnaces tungod pa sa mas pipila ka 20 tuig. Karon, ginsusunod an pag-evaluasyon han proseso han produksyon ug characteristics han espesyal nga transformers human an transformation han kompanya.

1. Diagram han Proseso han Produksyon han Espesyal nga Transformers

Ang produksyon han espesyal nga transformers mainhiwatugan an core production, insulation part production, winding winding, clamp ug fastener production, oil tank ug oil conservator production, assembly, ug transformer inspection ug testing, etc. Ang metal plates ug profiles dapat ispray ug shot blasted para matangtang an rust bago an blanking. Pagkahuman an clamps mahimong maputli, ang acid pickling ug phosphating surface treatment dapat isagdon. Ang oil tank, oil conservator, clamps, etc. dapat ispray paint ha anti-rust paint ug finish paint sumala han requirements han proseso.

1.1 Produksyon han Core Components
Unang unang, re-inspect an incoming silicon steel sheets, checking items sama an B-H characteristics, P₁₅/₅₀, surface resistance, ug mechanical properties. Pagkahuman, blank via longitudinal/transverse shearing sumala han nesting plan, stack an cut sheets para makabulag an core. Human matagumpay an inspection, hoist it ha test station, ug ang tester akan magpadaloy han specified tests. Human matagumpay an tests, bundle, shape, remove fasteners, ug transfer ha assembly.

1.2 Produksyon han Insulation Components

Unang unang, re-inspect an insulation materials. Pagkahuman, blank per the nesting plan, apply glue ha cardboard, stack, hot-press via steam, ug finally saw/mill to shape.
Ang insulation workshop mainhiwatugan an insulation parts, fasteners, ug clamps. Shaft parts gamiton an lathes/milling machines; box-type, special-shaped insulation parts gamiton an machining centers; planers handle plates/blocks. Additional, an electrostatic plate wrapping machine makes electrostatic plates, ug some parts gamiton an hot presses.

1.3 Winding of Windings

Prepare an raw materials (enameled wires, electromagnetic wires, insulation parts). Inspect an wire gauge, winding die dimensions. Select a winder based on the winding structure to wind the coil. After passing inspection, dry, preheat, ug send ha vacuum impregnation equipment. Post-impregnation, dry ha a vacuum tank; transfer ha assembly if qualified.

1.4 Produksyon han Welded Components

Unang unang, degrease/rust-remove an plates/profiles ha a shot-blasting room. Pagkahuman, blank ug weld. Small oil tanks/fin radiators gamiton an full welding line. Para han tanan welded parts (boxes, covers, corrugated tanks, etc.), apply anti-rust/insulating paint as required post-welding.

1.5 Assembly Process

Unang unang, prepare an qualified cores ug ready for upper yoke disassembly/assembly. Take an insulation parts/windings, assemble ug insert plates ha designated area. Pagkahuman, an operator self-inspects; pass ha quality inspector, then test an transformer body ha test station. After passing, proceed ha next steps (welding wires, installing covers/switches/bushings). Post-operation, inspect via a special quality inspector; dry ha a vacuum tank if qualified. After drying, fasten an body, hoist ha test semi-finished products. After passing, final-assemble: hoist ha final assembly area, secure bolts, install oil conservators, etc. Then, pressure/leak test, stand ha test station. Conduct final tests as required; touch-up paint ug store if qualified.

2 Analysis han Characteristics han Proseso

An upgraded special transformer production process may concise flow, smooth logistics, ensuring reliable production line operation. Easy to organize, suitable for mass production, efficient, ug quality-reliable. It fully considers environmental protection, occupational safety, ug energy-saving, aligning with international advanced tech. The flexible production line meets diverse market demands.

3 Guarantee han Proseso han Produksyon ha Quality & Equipment Matching

An special transformers made via this process meet standards like GB1094.1-1996, GB8286-1996, etc. Key indicators (load loss, no-load loss, no-load current) exceed standards.
An company uses advanced equipment (German Georg shearing lines, domestic winders). Years of operation show good process-equipment matching.

4 Comparison with Domestic and Foreign Similar Products

Taking the submerged arc furnace transformer for magnesia smelting as an example, it can automatically complete adjustable changes of voltage and current within the specified smelting time. The no-load loss of this product is 21% lower than that of domestic similar products, the no-load current is reduced by 30%, and the load loss is decreased by 22.3%. Compared with foreign similar products, the no-load loss is 15% lower and the load loss is 13% lower.

For general transformers, the energy consumption for electro - fused magnesia is 3200kW·h/t - 3500kW·h/t, while the transformers produced by this company have an energy consumption of 2300kW·h/t - 2600kW·h/t, saving nearly 1000kW·h of electricity per ton. The performance parameter comparison with foreign similar products is shown in Table 1.