Assembling transformers and inductors
Overview
This standard identifies the competences you need to assemble transformers and inductors, in accordance with approved procedures. This will involve selecting the correct components and materials, assembling the transformer or inductor components, connecting the coils, preparing lead-outs, making joints and terminations 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 assembly activities undertaken and to report any problems with the assembly activities, components or equipment that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with a 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 assembly techniques and procedures to transformers and inductors. You will understand the transformer or inductor being assembled and its application and will know about the assembly techniques, tools and methods, 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 carrying out the transformer or inductor assembly activities. 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 specific safety precautions to be taken whilst carrying out the activities (including any specific legislation, regulations or codes of practice relating to the activities, equipment or materials)
- the health and safety requirements of the work area and the activities, and the responsibility these requirements place on you
- the hazards associated with the activities, and how to minimise them and reduce risks
- the personal protective equipment and clothing (PPE) to be worn during the activities
- how to obtain and interpret drawings, planning sheets and records and other documents needed for the assembly activities
- the types of components used and how to ensure that they are fit to use in the assembly
- the preparation requirements for the components to be used in the transformer/inductor assembly activities
- the basic operating principles of the transformers and inductors being assembled
- the methods used to ensure a firm and rigid transformer/inductor assembly of appropriate mechanical strength
- the procedures to ensure correct electrical clearance between coils and earthed parts of the assembly
- the faults that can occur in assembly operations and how they can be prevented
- the methods used to connect the coils to the terminals and the importance of the tapping arrangements
- the methods used in preparing lead-out conductors and the methods used to remove insulation and tin them
- the procedures and methods used for making coil interconnections (such as delta group connections)
- the precautions taken when using soldering and brazing equipment and the associated dangers
- the methods used for re-insulating conductors
- the methods used to support the joined conductors and the common types of support packing
- the methods used to earth the transformer/inductor
- 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
Assemble transformers or inductors by carrying out all of the following activities:
- use the correct assembly 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 assemble transformers and inductors
- leave the work area in a safe and tidy condition
Use all of the following in the assembly activities:
- cores
- insulation materials
- foundation feet
- coils
- terminals
- frames
- support packing
- connections
Use five of the following tools and equipment during the assembly operations:
- soldering/brazing equipment
- mechanical hand tools
- electrical measuring equipment
- electrical hand tools
- mechanical measuring equipment
- other specialised tools/equipment
Carry out ten of the following assembly procedures:
- select the correct components and materials
- orientate and position the components correctly
- assemble the coils, cores and related components
- align the components
- set any required clearance
- make lead-outs (such as start, finish and intermediate tapping terminations)
- insulate the lead-outs
- carry out electrical bonding of the components
- carry out soldering/brazing of connections
- make compression connections (such as crimped)
- secure the components using mechanical fasteners/threaded devices
- torque setting
- apply threaded locking methods
Use appropriate equipment to carry out the six of the following required quality checks:
- positional accuracy
- orientation
- component security
- freedom from damage or foreign objects
- dimensions
- alignment
- completeness
Check assembled transformer or inductors 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