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During the early part of my working life I was a student apprentice at the firm of
Partridge Wilson & Co Ltd., whose trade name was Davenset. During my apprenticeship I learned about various transformer devices... From 10 mm cube to items that weighed half a ton.
As a radio ham I have often had a requirement for transformers of types that are
not available 'off the shelf' and as a result I have developed a technique of remanufacturing existing transformers and customising them to my own use.
Laminations
than plain steel, thus isolating each layer to a certain extent and reducing eddy currents that may occur perpendicular to the plane of lamination. Sometimes one or both sides of a lamination are sprayed with lacquer for insulation purposes.
Other forms are possible and the 'F' & 'F' type shown
right is one of these.
long side and fixing holes or notches are common at this point.
The 'holes' in the core are known as 'windows' or 'window spaces' and in an
assembled component they are filled by coils wound on a bobbin.
Bobbins these
days are mainly injection moulded in plastic, but larger ones often have paxolin or bakalised paper board cheeks.
Occasionally,
transformers are constructed with two or more independent bobbins, each having it's own winding(s). This method of construction is rare, but has it's uses at very high voltages (above 3,000 volts).
The windings or coils that are wound around these bobbins can be either single
coils or multiple ones. Single coils are a type known as 'Auto Transformers' and we will not deal any further with them on this page, as they are generally not applicable to the type of project that I get involved in.
Multiple coil types are known as 'double wound' and the windings fall into two
subdivisions... 'Primary' and 'Secondary' generally there is only one primary although it may be divided into two or more portions. Secondary windings may be of any number. Coils may be wound side by side on split bobbins or may be wound on top of one another with a suitable insulation between. Generally the primary or input winding is completed first as the innermost coil then layers of plastic or paper are placed over the completed primary and this is then used as a base upon which further windings are made.
Winding Coils
The Clamp
illustrated at right has been drawn as a brass one so that it stands out against the grey page background, mostly they are of steel although aluminium and brass are sometimes used if an air gap is incorporate d in the magnetic path.
Terminals
These are made in strips of 10 or 12 and sub divided (using a hacksaw) provides a break in any possible eddy current paths that would occur due to the to provide the correct number of ways to fixing bolts passing perpendicular to the suit the windings and tappings. plane of lamination.
Waste Free Laminations There is a way of punching 'E' & 'I' laminations that produces a pair of 'I's from
the window spaces of two 'E's.
This method utilises all of a sheet of rectangular material, hence the name... The
principal is illustrated at right.