Design And Construction Of An Automatic Transformer Winding Machine
The design and construction of an automatic transformer winding machine involve integrating advanced automation and precision engineering to streamline the winding process, enhance efficiency, and ensure consistent quality. This sophisticated machinery incorporates programmable logic controllers (PLCs), stepper motors, and sensors to automate winding operations, optimize wire tension, and regulate winding speed. Precision components such as servo-controlled winding heads and spindles are employed to achieve accurate coil winding and layering. The machine’s user interface facilitates easy programming and monitoring of winding parameters, while safety features such as emergency stop mechanisms and fault detection systems ensure operational reliability. Through meticulous engineering and innovation, this automatic transformer winding machine offers a reliable solution for high-volume production, meeting the demands of modern manufacturing processes.
ABSTRACT
In this project “microcontroller based automatic transformer winding machine” main objective is to bring out a machine which can implement the idea of automation in Transformer winding or any type of coil windings. The proposed system controls the speed of a winding machine in order to obtain the optimum stop point in terms of security and fast production. The system is based on a microcontroller and an extremely simple hardware. The system has been tested for two years and results evince a very good mean time between failures.
CHAPTER ONE
1.1 INTRODUCTION
Transformer winding machine allows you to make an electromagnetic coil that can be used for a variety of purposes. A transformer winding machine takes a copper or aluminum wire and winds it around a core or sometimes around air. The coils are usually wound around reels. During this process, the wires can be coated with a variety of materials that can provide some form of insulation. The types of wire, coiling, and insulation needed depends upon the particular application.
Automatic transformer winding machine main objective is to bring out a machine which can implement the idea of automation in Transformer winding or any type of coil windings. A transformer changes (transforms) an alternating voltage from one value to another. It consists of two coils, called the primary and secondary winding, which are not connected electrically. The windings are either one on top of the other or are side by side on an iron, iron-dust or air core.
A transformer works by electromagnetic induction: a.c. is supplied to the primary and produces a changing (alternating) voltage in the secondary. It is important that as much as possible of the magnetic field produced by the primary passes through the secondary. A practical arrangement designed to achieve this in an iron-cored transformer. In which the secondary is wound on top of the primary. You should also notice that the induced voltage in the secondary is always of opposite polarity to the primary voltage.
Too large a current in a transformer causes magnetic saturation of the core i.e. the magnetization of the core is a maximum and it is no longer able to follow changes of magnetizing current. Particular care is required when there is a d.c. component.
In block consists of keypad, Microcontroller, display, Stepper motor, Stepper driver circuit, coil winding machine. This demo works on the basis that the keypad provided is for entering the set values that is the number of windings can be given In case of transformer the primary winding & secondary winding can be entered. All the interfacing with Microcontroller is done through its I/O lines.
1.2 OBJECTIVES OF THE PROJECT
The objective of this work is to build a machine that is used for counting number of turns at transformer winding machine.
1.3 SIGNIFICANCE OF THE PROJECT
This machine has the ability of UP or DOWN counting. In case number of turns is more than required value, the count can be reduced to required value by rotating the transformer coil in reverse direction.
1.4 ADVANTAGES OF THE PROJECT
We are used to the previous manual winding, this also takes time and work efficiency is very low, and now a full-Technology developed an automatic transformer winding machine, so give us a lot of production efficiency. The main advantage of the following automatic transformer winding machine to introduce what it:
- can greatly reduce employee fatigue strength, improve work efficiency, saving tie.
- PLC program control, text display set parameters, and easy operation.
- can adjust the length of the winding, winding coils set tie line length, number of laps setting can yield count.
- for the AC power cord, DC power cord, USB data number, video cable, HDMI high-definition cable, and other various types of transmission lines using plastic bag tied into bundles core twisted purposes.
- employees simply lines on spools, automatic winding stepping foot switch, the machine will automatically tie lines around a good line into the mouth.
1.5 TYPES OF COIL WINDING MACHINES
There are different types of coil winding machines available.
Coil Winders
Coil winders are generally used for smaller jobs. They can be hand operated or have a winding drive that is controlled by a foot pedal. These coil winding machines are used in the production of solenoid coils, multi-section coils, and other such complex coils. Though they are small, they can reach up to speeds of 9000 RPM.
Medium-Duty Coil Winding Machines
These machines are more powerful than coil winders and take on higher production demands. Most of them are driven by potentiometers. They can wind various types of wires.
Heavy-Duty Coil Winding Machines
Heavy-duty motor coil winding machines are able to take care of extremely large amounts and are also very versatile in nature. For higher precision, most of these machines are equipped with LCD touch-screen monitors. These screens allow operators to have more control over speed.
1.6 PROJECT WORK ORGANISATION
The various stages involved in the development of this project have been properly put into five chapters to enhance comprehensive and concise reading. In this project thesis, the project is organized sequentially as follows:
Chapter one of this work is on the introduction to a microcontroller based transformer winding machine. In this chapter, the background, significance, objective limitation and problem of a microcontroller based winding machine were discussed.
Chapter two is on literature review of a microcontroller based winding machine. In this chapter, all the literature pertaining to this work was reviewed.
Chapter three is on design methodology. In this chapter all the method involved during the design and construction were discussed.
Chapter four is on testing analysis. All testing that result accurate functionality was analyzed.
Chapter five is on conclusion, recommendation and references.
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