Practically transformer manufacturing process

For 100 KVA transformer

Production flow chart

 Aluminum Conductor Strips

In many conventional transformers, the aluminum strip between the primary winding
(the closest to the core) and the secondary winding(s) serves as an electrostatic shield. This
shield must be connected to a good earth ground (not just a common ground) to discharge any
static charge brought into the transformer by the wires connected to the primary.
1
Conductor= 0.86
Strip=8.6× 3.8

 Winding
Two types of winding , LV winding and HV windings. (primary and secondary
winding). generally, core-type power transformers transformers are designed with similar
current density in the LV and the HV windings to set the temperature gradient to the same. If
you see two transformers with the same rating and voltage levels, and the only difference is
between the current density in the windings, it cause only higher current density in the windings,
so it has an effect mainly on temperature gradient

 Check winding dimensions

O.D of core=118mm
Height of core=480mm
Leg center of core=140mm
Base channel:- 790mm- length/height
192mm- width/breath

 L. V winding

L. V winding = Length=445mm. (440.5mm)

O. D of L.V =163mm
Width = 22mm
Air gap / inner insulation between core and L. V winding-3mm
I. D of L.V =120mm
Turns=72 turns -L.V turns/ aluminum strip
Aluminum strip size-
2
Length=11mm
Width =3mm

 H. V winding
Turns= 792mm
I.D =180mm/178mm

For total three limbs

H. V=792 turns in 1 coil Total coil=12
L. V=72 turns in 1 coil Total coil=3
For 1 turns of L. V =44 turns of HV
Total turns of L. V=216
Total turns of H.V =792×12
=9604 turns
216 turns × 44 turns
=9504 turns.

CRGO Lamination
C.R.G.O (Cold-rolled grain-oriented sheet steel) is used for reducing the core losses in
transformers.
Each type of steel has "grains" which consist of "domains". These "domains" are nothing but
electrical charges oriented in any random direction.

 Core loss= Hysteresis + Eddy Current Loss

Reduction of hysteresis loss:

(1)The size of the "grains" in a CRGO steel are purposely "grown" and made bigger and are
about 10 times the size of the grains in regular steel.
(2)The grains in CRGO steels are all aligned almost parallel to the direction of rolling of the
steel(i.e the length of the steel).

Reduction of eddy current loss:

A special carlite insulation coating on the steel being done so as to reduce the eddy current loss.