Design Phase:

Analysis of customer requirements and specification determination.

Transformer design, including magnetic circuit design, coil design, cooling system, etc.

Detailed production planning and process flow development.

Material Preparation:

Procurement of raw materials such as silicon steel (for magnetic circuits), insulation materials, coil materials, etc.

Quality inspection of raw materials to ensure compliance with specifications.

Coil Manufacturing:

Using conductors to create the transformer coils.

Winding the coils on support structures to form high and low voltage windings.

Ensuring the insulation performance of the windings.

Core Manufacturing:

Cutting and stacking silicon steel sheets to form the transformer core.

Core design and manufacturing are crucial for ensuring efficient energy consumption.

Assembly:

Assembling coils and cores to create the main structure of the transformer.

Installing support structures and other accessories.

Insulation Treatment:

Applying insulation treatments to the entire transformer to ensure electrical insulation performance.

Common insulation materials include paperboard, vulcanized fiber, epoxy resin, etc.

Cooling System Installation:

Installing the cooling system to ensure effective heat dissipation during transformer operation.

Cooling systems can be natural air-cooled or forced air-cooled.

Testing and Debugging:

Conducting performance tests, including electrical performance tests, insulation tests, cooling system tests, etc.

Debugging the transformer to ensure proper operation.

Packaging and Shipment:

Packaging the transformer to protect it from damage during transportation.

Shipping the finished product to the customer.

Throughout the manufacturing process, quality control is crucial to ensure the final product meets design specifications and possesses good performance and reliability.