From Core to Casing: The Complete Manufacturing Process of Dry-Type Transformers and Cooling Fans

From Core to Casing: The Complete Manufacturing Process of Dry-Type Transformers and Cooling Fans

Published by: Shanghai Angeda

Introductio

For buyers of power distribution equipment, the question is never just "what does it cost?" — it is "how was it built, and will it still be running reliably in ten years?"

At Shanghai Angeda, we specialize in two products that work together on the factory floor and in the field: transformatores sicci generis et ventilatores refrigerationis siccae . Every unit we ship passes through a carefully controlled manufacturing process — from raw material inspection to final high-voltage testing. This article takes you inside our workshop, step by step, so you can see exactly what goes into the equipment you buy.

Pars I: Quomodo Transformator Sicca Operatur Transformator Conficitur

A dry-type transformer is a safety-first alternative to oil-filled transformers: no oil, no leakage risk, fire-resistant, and maintenance-friendly. It is ideal for commercial buildings, industrial plants, data centers, metro systems, and renewable energy projects. Here is how we build one.

Step 1 — Material Selection and Incoming Inspection

Quality cannot be tested into a product — it must be built in from the very first batch of material. Every production run starts with strict incoming inspection:

Silicon steel (core material):

• we use cold-rolled grain-oriented (CRGO) silicon steel with high magnetic permeability and low core loss, precisely cut to reduce waste and optimize magnetic performance.

Cuprum:

• low-voltage windings use high-purity copper foil; high-voltage windings use precision copper conductors. Copper must meet conductivity standards, verified by testing before release to the workshop.

Epoxy resin system:

• casting-grade epoxy resin with carefully controlled filler and hardener ratios, checked for viscosity and curing characteristics.

Insulatio:

• aramid and polyester insulation materials with verified dielectric strength.

Only materials that pass incoming QC enter the production line.

Step 2 — Core (Iron Core) Manufacturing

The core is the "skeleton" of the transformer and the heart of its magnetic circuit:

Secare:

1. silicon steel coils are slit and cut to precise dimensions with burr-free edges — burrs cause inter-lamination shorts and increase losses.

Accumulatio:

2. laminations are stacked with interleaved, step-lap joints. This reduces no-load loss, excitation current, and operating noise.

Clamping and finishing:

3. Nucleus clauditur structuris fortissimis, superficies tractatur, et connectio ad terram additur ut accumulatio electrica statica prohibeatur.

Nucleus bene constructus est silentis, perdit minimas, et stabilitatem dimensionalem servat per decennia.

Gradus 3 — Fabricatio Vindicationum

Vindicationes determinant praestantiam electricam transformatoris et vim contra curtum circuitum:

Bobina tensionis infimae (typus folii):

• foliolum cupri vindicatur cum insulatione inter strata et sigillo terminali; deinde extremitates folii soldantur per technicam TIG ad connexiones resistentiam parvam et currentem magnam habentes. Vindicatio per folium excellentem vim contra curtum circuitum praebet.

Bobina tensionis altae (typus strati):

• vindicatio per strata sub tensione praecisa et regulata distributio uniformem campi electrici assurit.

Prætractamentum:

• post vindicationem, coilae siccantur in vacuo ut omnis umor ante incapsulationem amovetur.

Gradus 4 — Funditio in Vacuo (Incapsulatio per Resinam Fusam)

Haec est processus characteristicus qui transformatoribus nostris identitatem suam "siccum-typum" dat:

1. Vindicatio sicca in formam praecisam ponitur.

2. Resina epoxida, durcidor et pigmentum miscentur et sub vacuo exaerantur ut bollae aereae amoveantur.

3. Resina sub vacuo in formam infunditur, ut penitus penetret et nulli vacui loci relinquatur.

4. Spira in fornacibus temperaturis regulatis coquitur, per gradus calefaciendi ad optimas proprietates mechanicas et electricas.

Resultat spira inclusa, se ipsa extinguens, resistens ad umorem et pulverem, cum magna robore mecanico — quare transformatoribus resinosis sicci typi licet tuto in aedibus intus operari minima cura indigentibus.

Spire resinosae post funditionem sub vacuo et coctionem — cor uniuscuiusque transformatoris sicci typi.

Gradus 5 — Coniunctio Nuclei et Spire

Spire resinosae et nucleus in unitatem magneticam perfectam coniunguntur:

• Spire super crura nuclei collocantur cum pressione praevisa et exacta.
• Ductus derivationis, blocchi terminalium et barrae connexionis aptantur et ad specificatum momentum torque torquentur.
• Munimenta anti-vibrationis adhibentur ut sonus in aedificiis habitatis minimus sit.

Gradus 6 — Integratio Systematis Refrigerationis

Transformatoribus siccis naturaliter aer-coolantur (modus AN). Pro applicationibus quae maiora onera postulant, addimus ventilatores refrigerationis siccae (modus AF) ut aer per canales refrigerationis impellatur, quod capacitatem continuam transformatoris notabiliter augere potest absque unitatis incremento. Hic est locus ubi duae nostrae series productorum conveniunt — eadem ventilia quae separatim fabricamus in pacheta transformatorum nostrorum integrantur, aut ut kitae ad reficiendum praebentur pro installationibus iam existentibus.

Transformator siccus in suo receptaculo, cum ventiliis refrigerationis munitus ad capacitatem continuam augendam.

Gradus 7 — Examinatio Electrica (Porta quam omnis unitas transire debet)

Nullus transformator e fabrica nostra exire potest sine completo registro examinum. Examina fiunt secundum IEC 60076-11 (normam internationalem pro transformatoribus electricis siccis), inter quae:

• Mensura resistentiae avolationum
• Verificatio rationis tensionis et gruppi vectorialis
• Mensura amissae sine onere et currentis sine onere
• Load loss and impedance voltage measurement
• Induced overvoltage withstand test

Partial discharge (PD) measurement

• — a key indicator of insulation quality in cast-resin transformers
• Temperature rise test (verifies cooling performance, including AF fan-cooled operation)

Each unit ships with its own test report, so your incoming inspection team can verify performance against our factory data.

Step 8 — Final Inspection and Export Packaging

Before shipping: visual inspection, nameplate verification, accessory checklist, and moisture-protective packaging designed for long sea freight. Units are braced to survive handling and container transport.

The end of the road — 10 kV switchgear in a power distribution room, the working environment our transformers and cooling fans are built for.

Part 2: How a Dry-Type Cooling Fan Is Made

Ventilatores refrigerationis siccae sunt ventilatores axiales, qui aerem trans versus bobinas transformatorum et canales refrigerationis impellunt, ut dissipatio caloris augeatur. Officium eorum simpliciter videtur — sed fiducia in fabrica praecisa fundatur.

Gradus 1 — Designatio et materiae

Pale ventilatorum ex alligato aluminii fortissimo formantur, quod pro levi pondere, resistentia ad corrosionem, et efficiens fluxus aeris eligitur. Motores pro officio continuo dimensurantur et longam vitam designatam habent; et vectes pro parva cura in ambientibus industrialibus eliguntur.

Gradus 2 — Fabricatio palae et aequilibrio dynamico

Palaefacturae per formam metallicam ad profilum aerodynamicum fiunt; deinde singulae compositiones rotorum subiectae sunt ponderatio dynamica . Etiam minima inaequalitas vibrationes et sonos generat, qui vitam vectium breviant — aequilibratio in nostro processu non renuntiabilis est.

Gradus 3 — Involutio motoris et tractatio insulationis

Motor windings sunt machinaliter convolutae ad constantiam, deinde impregnatae sunt vernice isolante (aut impregnatae sub vacuo et pressione) ut umorem excludant et transferentiam caloris meliorent. Classis isolationis ad ambientem operativum ventili adaptatur.

Gradus 4 — Collectio et Obsignatio

Motors, paleae, et carapaces cum fixatoribus resistentibus corrosioni collecti sunt. Involucrum obsignatur ad Classe protectionis stili IP55 , protegens contra pulverem et aquae iactos — quod est necessarium pro installationibus transformatorum foris. Quadri fixationis ita designati sunt ut directe ad canales refrigerationis transformatorum aut ad tabulas involucrorum coniungantur.

Gradus 5 — Examinatio Rerum Gestarum et Durabilitatis

Omnis ventilator ante pactionem examinatur:

• Verificatio voluminis aeris fluentis et pressionis staticae
• Mensura gradus strepitus
• Mensura vibrationum
• Examinatio resistenciae isolationis et tolerationis dielectricae (hi-pot)
• Examinatio continuata durabilitatis ad stabilitatem thermicam confirmandam

Gradus 6 — Ultima Controla Qualitatis et Impachetatio

Ventilatores inspiciuntur visu, notantur cum valoribus electricis, et impachitantur cum angulorum sustentaculis protectivis pro navigatione exportationis.

Pars 3: Assistentia Qualitatis per Fabricam

Duo lineae productorum, unum systema qualitatis:

Plena Tractabilitas:

• omnis unitas portat numeros partium quae eam referunt ad partias materiarum primarum in productione usitarum.

Portae inspectionis in processu:

• materiae, nuclei, avolutiones, fusio, coniunctio, et examinatio finalis singillatim inspiciuntur antequam ad gradum sequentem progrediantur.

Documentatio:

• relationes examinum, certificata materiae, et acta inspectionis pro petitione habentur — utiles pro vestris propriis examinibus qualitatis aut exigentiis ultimorum consummatorem.

Pars 4: Cum Nobis Operari

Ut fabricator, plus quam productos catalogi communis offerimus:

Adaptatio ad Necessitates:

• ratings, voltage combinations, impedance, dimensions, mounting configurations, and fan airflow specifications can be engineered to your project.

OEM/ODM cooperation:

• we can produce to your specification, with your branding and packaging.

Export experience:

• robust sea-freight packaging and complete documentation for international shipments.

Conclusio

Behind every reliable dry-type transformer and cooling fan is a disciplined manufacturing process — careful material selection, precision winding, vacuum casting, dynamic balancing, and — above all — testing that leaves nothing to chance.

If you are planning a project and need a trusted manufacturing partner, we would be happy to discuss your requirements. Send us your specifications — rated capacity, voltage, standards, and target market — and our engineers will respond with a tailored proposal.

Contacat Angeda Shanghai — quality transformers and cooling fans, built to last.

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