A high-quality, low-loss transformer requires a standardized, meticulously crafted production process. Each step determines equipment losses, noise levels, stability, and lifespan. The complete production process is as follows:
1. Technical Design: Based on customer operating conditions and parameter requirements, complete electromagnetic schemes, structural designs, drawing output, and process verification, matching national standards and project-specific requirements;
2. Raw Material Inspection: Incoming core materials such as silicon steel sheets, copper wires, insulating components, transformer oil, and bushings undergo full inspection to eliminate inferior raw materials;
3. Core Processing: Precise CNC shearing, winding, annealing, and insulation treatment to eliminate stress and reduce no-load losses;
4. Coil Winding 5. **Core Assembly:** Precise assembly of the core and coils, lead wire welding, insulation wrapping, and pre-loading ensures coil compactness and reliable insulation.
6. **Vacuum Drying:** High-temperature, high-vacuum deep dehydration and degassing thoroughly removes moisture from the insulation, improving insulation performance and extending service life.
7. Tank Fabrication and Leak Testing:** Steel plate welding, anti-corrosion spraying, and pressure leak testing eliminate potential oil leakage.
8. Vacuum Oil Injection and Sealing:** Qualified transformer oil is injected under vacuum, allowed to settle and defoam, and then fully sealed.
9. Comprehensive Factory Testing:** All routine tests are completed according to GB1094 national standard. After passing the tests, the transformer is labeled, packaged, and delivered.
