Prosesa Pêşkeftina Nahaçîna Transformers yên Bijarkir: Dîjîna Prosesa, Kontrola Ciyayetî û Standardekirina Berhemdariyê

Yek çarçoveyên taybetandî yên transformatoreya xusûsî hatîn piramend e ku ji bo zêde di 20 sallan de transformatoreya xusûsî yên jî hene an jî transformatoreya şiftî ya şifteya rastkirina ve transformatoreya şifteya rastkirina ji bo elektroliz û transformatoreya şifteya furnacê yên şevirandin da. Niha, bir evalek dibe ser rêza peregrafiya bikaranîna û xasîyatên transformatoreya xusûsîyan pas werdikeşeya kompaniyeyê.

1. Şema Peregrafiya Bikaranîna Transformatoreya Xusûsî

Bikaranîna transformatoreya xusûsî ya peyserî hatine cihêrên peregrafiya bikaranîna nivîsan, bikaranîna baha xusûsî, bikaranîna kurtina şifte, bikaranîna kelem û fastener, bikaranîna tankê ya ewle û oil conservator, keskena û testkirina transformatoreya. Pelên metal û profiller ên divê bi serbistîna spray û shot blasting serfiraz bike vêlînkirina qurê xabûr. Pas serfiraz bike vêlînkirina qurê xabûr, kelemên divê serfiraz bike şifteya acid pickling û phosphating. Tankê, oil conservator, kelem û yekarên din divê bi serbistîna peregrafiya bike serfiraz bike sprey - keranî û serpilana nîvekirina.

1.1 Bikaranîna Nivîsên Cihêr
Yekem, serfiraz bike re-inspection pelên silikon steel vebare, kontrol bike mînasan we B - H characteristics, P₁₅/₅₀, resistance surface, û xasîyatên mekanîk. Demeh, blank bi serbistîna plana nesting, stack pelên kirin vê biçin cihêr. Pas serfiraz bike test, liq bike test station, û tester ên divê serfiraz bike testên nîşandan. Pas serfiraz bike test, bundling, shaping, remove fasteners, û transfer to assembly.

1.2 Bikaranîna Baha Xusûsî

Yekem, serfiraz bike re-inspection baha insulation. Demeh, blank bi serbistîna plana nesting, apply glue to cardboard, stack, hot-press bi serbistîna steam, û demeh saw/mill to shape.
Insulation workshop peyserî bike baha insulation, fasteners, û kelem. Shaft parts use lathes/milling machines; box-type, special-shaped insulation parts use machining centers; planers handle plates/blocks. Additionally, an electrostatic plate wrapping machine makes electrostatic plates, and some parts use hot presses.

1.3 Winding of Windings

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

1.4 Bikaranîna Yekarên Welded

Yekem, degrease/rust-remove plates/profiles in a shot-blasting room. After passing, blank and weld. Small oil tanks/fin radiators use a full welding line. For all welded parts (boxes, covers, corrugated tanks, etc.), apply anti-rust/insulating paint as required post-welding.

1.5 Process of Assembly

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

2 Analysis of Process Characteristics

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

3 Guarantee of Production Process on Quality & Equipment Matching

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.
The 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.