Prosesi Na Zamani Da Yake Da Karkashin Fadada na Transformers Masu Nau'i: Tsarin Prosesi Aikatako da Kulaitya da Kulaiki Don Idanarwa

Wani aikatau mai girman gina abubuwa masu shaida, wanda ya yi aiki a kan gina abubuwa masu shaida kamar split-phase-shifting rectifier transformers, rectifier transformers for electrolysis, da kuma transformers for submerged arc furnaces zuwa harshe na 20. Yanzu, ana bayyana tsarin aiki da sauransu na abubuwa masu shaida ba a kan juna ta hanyar gwamnati.

1. Tsarin Aiki da Sauransu na Abubuwa Masu Shaida

Gininta abubuwa masu shaida sun hada da gina core, gina insulation part, winding, gina clamp da fasteners, gina oil tank da oil conservator, assembly, da kuma test da inspection of the transformer, kamar haka. Ana samun plates da profiles don spray da shot blasting don cuciya rust saboda blanking. Ba a tafiya slag daga clamps, ana yi acid pickling da phosphating surface treatment. Oil tank, oil conservator, clamps, kamar haka suke ana painti da anti-rust paint da finish paint mafi yawan alama a cikin tsari.

1.1 Ginar Core Components
Kafin karkashin silicon steel sheets, ana yi re-inspection, tattaunan B-H characteristics, P₁₅/₅₀, surface resistance, da kuma mechanical properties. Kafin haka, ana blank via longitudinal/transverse shearing mafi yawan alama, ana stack cut sheets don bincika core. Kafin haifar da test, ana lift it to the test station, kuma tester zai yi tests masu alama. Kafin haifar da tests, ana bundle, shape, remove fasteners, da kuma transfer to assembly.

1.2 Ginar Insulation Components

Kafin karkashin insulation materials, ana yi re-inspection. Kafin haka, ana blank per the nesting plan, apply glue to cardboard, stack, hot-press via steam, da kuma saw/mill to shape.
Insulation workshop ya fi yin insulation parts, fasteners, da kuma clamps. Shaft parts suna amfani da lathes/milling machines; box-type, special-shaped insulation parts suna amfani da machining centers; planers suna handle plates/blocks. Duk da haka, electrostatic plate wrapping machine yana yi electrostatic plates, da kuma wasu parts suna amfani da hot presses.

1.3 Winding of Windings

Ana yanayi raw materials (enameled wires, electromagnetic wires, insulation parts). Ana inspect wire gauge, winding die dimensions. Ana select a winder mafi yawan alama don wind the coil. Kafin haifar da test, ana dry, preheat, da kuma send to vacuum impregnation equipment. Kafin impregnation, ana dry in a vacuum tank; kafin haifar da test, ana transfer to assembly.

1.4 Ginar Welded Components

Kafin karkashin plates/profiles, ana degrease/rust-remove a cikin shot-blasting room. Kafin haifar da test, ana blank and weld. Small oil tanks/fin radiators suna amfani da full welding line. Don all welded parts (boxes, covers, corrugated tanks, kamar haka), ana apply anti-rust/insulating paint mafi yawan alama ba a kan welding.

1.5 Assembly Process

Kafin karkashin qualified cores, ana prepare for upper yoke disassembly/assembly. Ana take insulation parts/windings, assemble and insert plates in the designated area. Kafin haka, operator yana self-inspect; kafin haifar da test, ana pass to quality inspector, then test the transformer body at the test station. Kafin haifar da test, ana proceed to next steps (welding wires, installing covers/switches/bushings). Ba a karkashin operation, ana inspect via a special quality inspector; kafin haifar da test, ana dry in a vacuum tank. Kafin drying, ana fasten the body, lift to test semi-finished products. Kafin haifar da test, ana final-assemble: lift to the final assembly area, secure bolts, install oil conservators, kamar haka. Kafin haka, ana pressure/leak test, stand at the test station. Ana conduct final tests mafi yawan alama; kafin haifar da test, ana touch-up paint and store.

2 Analysis of Process Characteristics

Tsarin gininta abubuwa masu shaida ta hanyar gwamnati yana da flow mai kyau, smooth logistics, ta daidaito hankali ga reliable production line operation. Ya fi yin aiki, suitable for mass production, efficient, da kuma quality-reliable. Yana da hankalin environmental protection, occupational safety, da kuma energy-saving, ta daidaito international advanced tech. Flexible production line yana da muhimmanci a kan yin tasirin market masu shaida.

3 Guarantee of Production Process on Quality & Equipment Matching

Abubuwa masu shaida wadanda an yi a cikin wannan tsari suna da standards kamar GB1094.1-1996, GB8286-1996, kamar haka. Key indicators (load loss, no-load loss, no-load current) suna da ma'ana masu yawa saboda standards.
Aikatau ya amfani da equipment masu yawa (German Georg shearing lines, domestic winders). Shekaru dubu sun nuna process-equipment matching mai kyau.

4 Comparison with Domestic and Foreign Similar Products

Idan a kunna example, submerged arc furnace transformer for magnesia smelting, yana iya automatically complete adjustable changes of voltage and current within the specified smelting time. No-load loss of this product is 21% lower than that of domestic similar products, no-load current is reduced by 30%, and load loss is decreased by 22.3%. Compared with foreign similar products, no-load loss is 15% lower and load loss is 13% lower.

For general transformers, 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. Performance parameter comparison with foreign similar products is shown in Table 1.