Winding transformer and inductor coils
Overview
This standard identifies the competences you need to wind transformer and inductor coils, in accordance with approved procedures. This will involve selecting the correct components and materials, setting up the coil winding machines, winding and constructing transformer and inductor coils, cutting and forming insulation, making joints and terminations, preparing the coils for processing and checking the electrical and mechanical integrity of completed assemblies. You will be required to select the appropriate tools and equipment to use, based on the operations to be performed and type of components to be fitted and to check that they are in a safe and serviceable condition. In carrying out the operations, you will be required to follow laid-down procedures and specific assembly techniques. The assembly activities will also include making all necessary checks and adjustments to ensure that components are correctly positioned and free from damage.
Your responsibilities will require you to comply with organisational policy and procedures for the component assembly activities undertaken. You will report any problems with the components or coil winding activities that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with the minimum of supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you carry out.
Your underpinning knowledge will provide a good understanding of your work and will provide an informed approach to applying transformer and inductor coil winding techniques and procedures. You will understand the transformer and inductor coil winding processes, their application and the manufacturing techniques. You will know about the types of components used, in adequate depth to provide a sound basis for carrying out the activities to the required specification.
You will understand the safety precautions required when setting, adjusting and operating the coil winding equipment. You will be required to demonstrate safe working practices throughout and will understand the responsibility you owe to yourself and others in the workplace.
Performance criteria
You must be able to:
- work safely at all times, complying with health and safety legislation, regulations, directives and other relevant guidelines
- follow the relevant instructions, assembly drawings and any other specifications
- ensure that the specified components are available and that they are in a usable condition
- assemble the components in their correct positions using appropriate methods and techniques
secure the components using the specified connectors and securing devices
check the completed assembly to ensure that all operations have been completed and it meets the required specification
- deal promptly and effectively with problems within your control and report those that cannot be solved
- ensure that work records are completed, stored securely and available to others, as per organisational requirements
- leave the work area in a safe condition on completion of the activities, as per organisational and legal requirements
Knowledge and Understanding
You need to know and understand:
- the health and safety requirements of the area in which the coil winding activity is to take place and the responsibility these requirements place on you
- the importance of wearing personal protective clothing (PPE) and other appropriate safety equipment during the coil winding activities
- the hazards associated with the type of coil winding activities being undertaken and how the risks can be minimised
how to obtain and interpret drawings, planning sheets, records and other documents needed for the coil winding activities
the factors to consider when selecting conductors to produce transformer and inductor coils (such as round section, rectangular, foil, sheet, hollow section, aluminium, copper, bare, insulated)
- the factors that influence the choice of size and type of coil conductors
- the basic operating principles of the transformers and inductors being wound
- the methods used to set up the coil winding machine with regard to wire traverse, pitch, gear ration and tension
- the methods used to produce helical, spiral, disc, sandwich and distributed crossover types of coil windings
- the methods used to minimise magnetic leakage
- the procedures for cutting and forming insulations
- the purposes of cylinder wraps, wrap/duct inter-layer, parallel and tapered coil edge packing, inter-coil wrap/cylinder/duct, lead-out sleeving tape, key ducts and spacers, common end washers and finishing banding tape pieces
- how coils are prepared for impregnating and curing and the methods used to do this
- the methods used to cut lead-out conductors to size and shape
- the procedures for cutting the high and low voltage terminations and tappings of the coil winding
- the methods used to earth the transformer or inductor coil
- the methods used to strip and clean electrical conductors before jointing and the methods of jointing used
- the procedures used when hand soldering joints and the hazards associated with using soldering equipment
- the visual checks and preparation requirements for components to be used in transformer and inductor coil wining activities
- the methods and tools/equipment used to transport, handle and lift the components into position
how to check that the tools/equipment are within current certification dates, free from damage and defects , in a safe and usable condition, and configured correctly for purpose
the extent of your own responsibility and whom you should report to if you have problems that you cannot resolve
- how to access, use and maintain information to comply with organisational requirements and legislation
Scope/range
Scope Performance
Carry out all transformer or inductor coil winding activities, using all of the following:
- use the correct drawings, specifications and job instructions
- adhere to health and safety regulations, systems and procedures to realise a safe system of work
- ensure that components are free from damage, foreign objects, dirt or other contamination
- check that all tools and equipment are within calibration date, where appropriate
- use safe and approved techniques to wind transformer and inductor coils
- leave the work area in a safe and tidy condition
Carry out coil winding operations using twelve of the following materials and components:
- conducting materials
- coil edge packing
- finish/banding tapes
- insulating materials
- inter-coil wraps
- lead-out conductors
- joining materials
- lead-out sleeving
- bobbins
- foundation feet
- lead-out tapes
- frames
- clamps
- key ducts
- laminations
- core and tie bolts
- spacers
- sleeving
- earth strips
- common end washers
- fixing material
Use all of the following equipment and tools for the coil winding and assembly operations:
- coil winding machine
- measuring equipment
- insulation cutting and forming equipment
- mechanical hand tools
- tinning equipment
- electrical hand tools
- laminate cutting and punching machine (as appropriate)
Complete all of the following coil winding and assembly procedures:
- select conductors (such as round, rectangular, foil, sheet, hollow section, aluminium, copper, bare, insulated)
- select materials (such as insulation, joining)
- set coil winding cutting machine (such as wire traverse, pitch, gear ratio and tension, joining tool)
- cut and form insulation such as wraps/cylinder, inter-l layer/wrap/duct, parallel and tapered coil edge packing, inter-coil wrap/cylinder/duct, lead-out sleeving/tape, key ducts and spacers, common end washers, finish/banding tape)
- cut and form lead-out conductors (such as low and high voltage terminations and tappings)
- wind coils using different conductors (such as flat and edge wound, multiple stranded)
- wind coils using various techniques (such as distributed crossover, helical spiral, disc)
- make terminations (such as high voltage insulated, flexible fly leads, tappings, heavy section single and multiple form lead-outs and busbars)
- make lead-outs (such as high and low voltage, radial off-coil face, axial from coil ends, left/right, front/back of coil and staggered)
- assemble coils (such as multi-sectional, multiple coils, lead-outs, tappings, insulation)
- prepare coils for processing (such as impregnating, curing)
Check completed transformers/inductor coils comply with one of the following quality and accuracy standards:
- organisational drawings and procedures
- customer drawings and requirements
current industry standards, codes of practice and procedures
other international standards