How to rewind a transformer: step-by-step instruction

The transformer is an aggregate designed to transmit electricity with changed indicators over the network to the end user. This equipment is characterized by a specific scheme. Transformers can lower or increase the voltage.

Over time, the core may require rewinding. . In this case, the radio amateur is faced with the question of how to wind the transformer . This process takes a lot of time and requires concentration of attention. However, there is nothing complicated in rewinding the circuit. For this, there is a step-by-step instruction.

Design

The transformer operates on the principle of electromagnetic induction. It can have a different design of the magnet actuator. However, one of the most common is the toroidal coil. Its design was invented by Faraday. или прибор любой другой конструкции, необходимо изначально рассмотреть конструкцию его катушки. To understand how to wind a toroidal transformer or device of any other design, you must first consider the design of its coil.

Toroidal devices convert an alternating voltage of one power to another. There are single-phase and three-phase designs. They consist of several elements. The structure of the structure includes a core of ferromagnetic steel. There is a rubber gasket, primary, secondary winding, as well as insulation between them.

The winding has a screen. Insulating material is covered with a core. Also used fuse, fasteners. To connect the windings in a single system, a magnetic actuator is used.

Winding fixture

Toroidal transformers can be of different types. This must be taken into account in the process of creating the outline. , 12/220 или прочие разновидности можно при помощи специального инструмента. The transformer 220/220 , 12/220 or other varieties can be wound with a special tool.

To simplify the process, you can make a special device. It consists of wooden racks, which are fastened together by a metal rod. It has the shape of a hilt. This spit will help quickly wind the contours. The stick should not be thicker than 1 cm. It will permeate the framework through and through. With the help of a drill perform this process will be easier.

The drill is attached to the table. It will be parallel. The handle must rotate freely. The rod is inserted into the drill chuck. Before this, a metal shoe should be fitted with a shoe with the frame of a future transformer. The rod may have a thread. This option is considered preferable. The shoe can be clamped on both sides with a nut, textolite plates or wood planks.

Other tools

импульсный, ферритовый или прочие разновидности конструкций, необходимо подготовить еще несколько инструментов. To wind the transformer 12/220, impulse, ferrite or other types of structures, it is necessary to prepare several more instruments. Instead of the above construction, you can use an inductor from the phone, a device for rewinding the film, a machine for a spool with a thread. There are many options. They should ensure smoothness, uniformity of the process.

You will also need to prepare the device for unwinding. By its principle, similar equipment is similar to the above devices. However, in the reverse process, it is possible to rotate without a handle.

In order not to count the number of turns independently, you should purchase a special device. It will take into account the number of turns on the coil. For these purposes, an ordinary water meter or a bicycle speedometer may come up. Using a flexible roller, the selected meter is connected to the winding equipment. You can count the number of coil turns orally.

Calculations

необходимо произвести расчеты. To understand how to wind a pulse transformer, you need to make calculations. If you rewind an already existing coil, you can simply remember the original number of its turns and purchase a wire of identical cross-section. In this case, you can do without calculations.

But if you want to create a new transformer, you need to determine the number and type of materials. For example, for a device with a workload of 12 to 220 V, an apparatus of 90 to 150 W of power is required. You can take the magnetic actuator, for example, from an old TV set. The cross-section of the conductor is determined in accordance with the power of the unit.

The number of coil turns is determined for 1V. This indicator is equivalent to 50 Hz. The primary (П) and secondary (В) windings are calculated as follows:

• P = 12 x 50/10 = 60 turns.
• B = 220 x 50/10 = 1100 turns.

To determine the currents in them, the following formula applies:

• Tn = 150: 12 = 12.5 A.
• Tv = 150: 220 = 0.7 A.

The result should be taken into account when selecting materials for creating a new device.

Insulation of layers

или другую разновидность приборов, необходимо изучить еще один нюанс. To reel a ferrite transformer or other kind of instrument, it is necessary to study one more nuance. Isolated materials should be installed between certain conductor layers. Most often, a condensate or cable paper is used for this. All necessary materials can be purchased at specialized stores. The paper must have sufficient density, be even without lumens or openings.

Between the individual coils, the insulating layers are made of stronger materials. The lacquer is most commonly used. It is covered with paper on both sides. This is also necessary for leveling the surface before winding. If you could not find the lacquer, you can use paper folded in several layers instead of it.

Paper is cut into strips, the width of which should be greater than the contour. They should extend beyond the edges of the winding by 3-4 mm. Excess material will be tucked up. This will protect the edges of the coil well.

Frame

, следует уделить внимание каждой детали этого процесса. To understand how to properly wind the transformer , you should pay attention to every detail of this process. Prepare the insulation, wire and tools, you need to make a frame. For this you can take the cardboard. The inner part of the frame must be larger than the core core.

For the O-shaped magnet actuator, 2 coils must be prepared. For an Ш-shaped core, one circuit is required. In the first variant, the round core must be covered with an insulating layer. Only after that they start winding.

If the magneto-drive is an S-shaped magnet, the frame is cut out of the sleeve. Brushes are cut from cardboard. The coil in this case will need to be wrapped in a compact box. Brushes are put on sleeves. After preparing the frame, you can start winding the conductor.

Step-by-step instruction for winding

будет достаточно просто. Winding the transformer yourself will be easy enough. To do this, the coil with the wire should be installed in the equipment for unwinding. It will remove the old wire. The frame of the future transformer needs to be put in the winding equipment. Then you can make rotational movements. They should be measured, without jerks.

During this procedure, the wire from the old coil will be moved to the new frame. Between the wire and the surface of the table, the distance should be at least 20 cm. This will put your hand and fix the cable.

On the table, you need to put all the necessary tools and equipment in advance. At your fingertips there should be insulation paper, scissors, sandpaper, a soldering iron (included in the network), a pen or a pencil. One hand needs to turn the handle of the winding device, and the second one - to fix the conductor. It is necessary that the coils are laid evenly, evenly.

Recommendations on winding

, следует уделить внимание последующим операциям. Considering step-by-step instructions on how to wind a transformer , you should pay attention to subsequent operations. After laying the conductor, the frame must be insulated. Through the hole it is necessary to pass the end of the wire, taken out of the circuit. Fixation will be temporary.

Experienced hams recommend that you practice first before winding. When it turns out to impose turns exactly, you can start working. The tension angle and the wires must be constant. Each next layer is not required to be wound up to the stop. Otherwise, the conductor can slide off the place designated for it.

In the process of winding the threads, you must set the counter to zero. If it does not, you need to say the number of turns of the wire aloud. At the same time, you should concentrate as much as possible in order not to lose count.

The insulation should be pressed with a ring of soft rubber or glue. Each successive layer will be 1-2 turns less than the previous one.

Connection Process

, необходимо изучить процесс соединения проводов. Considering how to wind a transformer , it is necessary to study the process of connecting the wires. If the vein breaks off during winding, a soldering process should be performed. This procedure may be required even if it is initially intended to create a contour of several separate pieces of wire. The spike is made in accordance with the thickness of the wire.

For wire thicknesses up to 0.3 mm, you need to clean the ends by 1.5 cm. Then they can be simply twisted and soldered with an appropriate tool. If the vein is thick (more than 0.3 mm), you can solder the ends directly. Twisting in this case is not required.

If the wire is very thin (less than 0.2 mm), it can be welded. They are twisted without performing a stripping procedure. The connection point is brought into the flame of a lighter or an alcohol lamp. At the junction, there should be an influx of metal. The place of connecting the wires must be necessarily isolated with a lacquer or paper.

Test

следует учесть еще несколько рекомендаций. After examining the procedure for winding the transformer, several other recommendations should be considered. The number of turns of a thin conductor can reach several thousand. In this case, it is better to use special counting equipment. The winding is protected from above with paper. For a thick conductor, no external protection is required.

Further, the transformer operation test is performed. Its primary circuit is connected to the network. A lamp is connected in series to the power source. This will detect a short circuit.

To assess the reliability of isolation, it is necessary to touch the output of each output of the network circuits in turn. The procedure of verification should be carried out very carefully. It is necessary to exclude the possibility of electric shock.

After reviewing the step-by-step instruction for winding the transformer, you can repair the old one or create a new device. With a clear adherence to all of its points, it is possible to create a reliable, durable unit.