Mag-Tran was able to complete production of this custom 700 kVA transformer within 5 weeks.
Facilities and Equipment
Mag-Tran facilities are located in two adjacent buildings with over 16,000 square feet of floor space. Over two-thirds of this space is dedicated to coil winding, assembly, and test functions.
The winding process required specialized winding combs, air ducts for cooling, and the utmost attention to insulation integrity. Each facet of the winding of the coils was closely scrutinized and inspected throughout the manufacturing process. A coil test was performed on each individual coil to ensure that the proper number of turns was present and a HiPot test was used to confirm that the coils were adequately insulated.
The assembly of the transformer, which included putting the coil on the core, required extreme finesse and attention to detail. A high precision miter-cute, step-lap design was used to further increase efficiency. Once assembled, the following tests were performed on the transformer to ensure that all the work met Mag-Tran’s quality requirements and that the unit was functioning properly:
- Turns Ratio Test
- Double-Induced Test at 400 Hz
- HiPot Test to 30 kVrms
- Short Circuit Impedance Test
- DC Resistance Test
- Exciting Current Test
- Open Circuit Voltage Test
Impregnation and Bake-Out
The units were double-dipped in epoxy resin. This process helps to solidify the core and coil and decreases audible noise.
Tests
- HiPot Test to 30 kVrms
- Polarity Test
- Open Circuit Test
Manufacturing Capabilities/Processes
Close integration between several departments (e.g., Sales, Drafting, Manufacturing, Purchasing, and Shipping) was needed to ensure the completion of this project. Daily production meetings were held during the manufacturing process to further this goal.
Sales Department
The Sales Department responded to all customer requests and concerns. Any specification alterations that needed to be made were communicated between the Customer and the Engineering Department through the Sales Department.
Engineering Department
The Engineering Department was responsible for taking the Customer’s specification and turning it into a working design. Engineering worked closely with the Drafting Department to ensure the construction worked as designed as well as with the Manufacturing Department to ensure the theoretical design made by drafting worked as a real-world application in both construction and operation. Engineering helped answer production questions as they arose.
Drafting Department
The Drafting Department was responsible for taking a working design from the Engineering Department and turning into a theoretical design the Manufacturing Department would use to build the transformers. The Drafting Department was also responsible for ensuring the drawings were always up to date with the Customer’s specification alterations and in-process changes.
Manufacturing Department
The Manufacturing Department took the designed drawings and worked closely with Engineering to ensure the transformer was built to operating conditions.
Purchasing Department
The Purchasing Department works with all departments to ensure the correct materials are ordered and arrive on time.
The Shipping Department
The Shipping Department ensures the unit is packaged and crated appropriately so that all contents are secured for their destination. The Shipping Department also helps to ensure the unit is shipped on time.