Transformer Rewinding Machine With Digital Display

ABSTRACT

This project is on design and construction of transformer rewinding machine with digital counter. A coil winding machine is a machine for winding coil onto a spool, bobbin and many more. This coil winding machine is one of types of winding machine that available in industries today. From multi speeded machines to medium, large and extra-large machines, these machines come in various types and categories, performing a range function. The common applications for a coil winding machine are to wind coils for transformer, inductors, motor and chokes. To complete a coil using manual coil winding machine will be inconvenience and waste of time. Therefore, fabrication of coil winding machine will be done in this project which is controlled by one stepper motor using software program.

CHAPTER ONE

INTRODUCTION

1.1                                          BACKGROUND OF THE PROJECT

Typically, a winding machine winds a material such as metal wire, thread, or paper, onto a core, spool, or bobbin. There are several different types of winding machines, from simple manual feed machines to complex computer-numeric-control (CNC) machines. Some of the more common uses for winding machines are coil winding, rope winding, and continuous filament winding. Many industries use these devices, including textile, electronics, and wire industries (Pansini, 2009).

A manual winding machine usually has a core on a spindle and the user feeds wire, rope, or other material onto the core. The user controls the spindle speed and feeds the material through user hand, guiding it to control the tension and load pattern. These simple machines may be of a bench-top size or large stand-alone winder.  Winding machines may be used for transformer or motor (Henry, 2011).

Transformer rewinding machine is a machine for rewinding coil in a transformer. This transformer rewinding machine is one of types of winding machine that is available in industries today. The transformer rewinding machine can be classified according to speed levels and capacity. From multi speeded machines to medium, large and extra-large machines, these machines come in various types and categories, performing a range function and can be manual, automatic, analogue or digital (Peri, 2010).

Transformer rewinding machine with digital display design is dictated by a coil’s complexity, material tension limitations, machine versatilities, and automation/operator intervention, production volume and budgetary considerations (Bill, 2013).

1.2                                          PROBLEM STATEMENT

The problem to be solved in this project will include;

1. The design an automatic transformer rewinding machine
2. Integrating a digital counter into the transformer rewinding machine
3. Sourcing of local components for construction of automatic transformer rewinding machine
4. Production of a user friendly and easy to operate automatic transformer rewinding machine

1.3                                          OBJECTIVES OF THE PROJECT

The aim of this project is to design and construct a transformer rewinding machine with digital counter.

Basically, this project has four main objectives;

1. To design an automatic transformer rewinding machine
2. To integrate a digital counter into the transformer rewinding machine
3. To source local components for construction of automatic transformer rewinding machine
4. To produced a user friendly and easy to operate automatic transformer rewinding machine

1.4                                                      SCOPE AND LIMITATION 

The design of the machine will be limited to a table size winding machine. This study limited its scope for winding coils of small transformers of about 12KV with an input voltage of 220v-5v dc and an output voltage of 5v,the number of turns the machine can wind is in the range of 0-999 turns . The size of the copper wire for winding other machines like large turbine, heavy transformers e.t.c that has 14 to 34 SWG or specifically 0.078-0.3125 diameter copper wire is beyond the machine capability. Specifically indoor appliances commonly found in household like electric fan, grinder.

1.5                                                      IMPORTANCE OF THE PROJECT

The significance of this project cannot be overemphasized this is because it would serve as a low cost machine when produced in bulk. And this will aid the small business man who cannot afford to buy the bigger machine by affording this one. Also it can be used for training students in winding of small transformers & relay coils.

1.6                                    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.

1.7                                                  DEFINITION OF TERMS

COIL(s): The end result of a wire, tube, or bar in a continuous loop referred to as “turn” to create a Helix spiral.

COIL ASSEMBLY: Is when parts (ex: plastic) are added to the coil to be considered complete.

COIL BENDING: Is when the end of a coiled material is curved or bent in different directions.

COIL WINDING: “coil” in this sense refers to the wire or conductor and “winding” is the turn/loop of the wire to create the end result.

Over Winding: The winding of a second coil on top of another coil.

TOROIDS: Is a ring-shaped core that can be made of ferrite (magnetic) or out of dust-iron that is used to wind wires inductors.

TOROID COIL: Is sometimes known as “Toroid Inductor” and is used for low frequencies.  It is a coil that is wire wound on a toroid.

TUBE BENDING: Is when a hollow tube of various sizes and material (such as copper) is bent to form a specific shape.  The tube can be curved or angled to create a unique shape based on the functionality and need of the project. The tube size and thickness can vary to ensure the curve or angle follows the original OD of the tube.

TUBE WINDING: Is when a hollow tube of various sizes and material (such as copper) are wound in a continuous loop/turn. A coil is created when tube is wound on a custom mandrel creating a spiral like shape with or without spacing, thus creating a coil. These tubes are utilized in many different industries to create a path for energy or used to heat or cool liquid.

TURNS:  Is the number of loops in a coil(s).

1.9                                        PROJECT WORK ORGANIZATION

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 micro controller based winding machine. In this chapter, the background, significance, objective limitation and problem of a micro controller based winding machine were discussed.

Chapter two is on literature review of a micro controller 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.