Case Study: Improvement of a Transformer with Unstable Electrical Characteristics
Achieving stability in characteristics through the review of the immersion process.
A case study of stabilization through optimization of the impregnation process for a transformer that does not exhibit electrical characteristics.
【Consultation Details】 We received the following consultation from a device manufacturer: - The prototype transformer does not exhibit the expected electrical characteristics. - There is variability in the measurement values, and the characteristics are unstable. There should have been no issues in the design, but the actual prototype did not perform as expected, and the cause could not be identified. The request this time was for: "I would like you to impregnate it while the core is assembled." This was the specified process. Issues The electrical characteristics of the transformer were: - Unstable - Not reaching the design values To establish it as a product, stabilization of the electrical characteristics was necessary. < Hypothesis from Akita Transformer > After reviewing the situation, Akita Transformer proposed the following hypothesis: There is a possibility that the impregnation process is affecting the characteristics. Depending on how the impregnation resin enters and the state of the magnetic circuit, it is believed that there may be an impact on the coil and magnetic characteristics.
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<Implemented Measures> Therefore, we conducted trials not only in the specified process but also through several methods. - Impregnation with the core assembled - Impregnation with the coil alone - Change in assembly order - Verification through condition changes We performed multiple prototypes and evaluations while changing the order of the processes. <Improvement Results> Ultimately, we changed the process to impregnate the coil alone and then assemble the core, resulting in: - Stable electrical characteristics - Meeting design values - Elimination of characteristic variation <Key Points of This Case> In this project, we approached it from the perspective of considering processes that establish characteristics rather than manufacturing as requested. By reviewing the order of processes and the timing of impregnation, we were able to resolve the issues with electrical characteristics.
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【Areas of Support at Akita Trans】 At Akita Trans, we offer support for: - Custom transformer manufacturing - Winding process - Impregnation process - Electrical testing / Dielectric strength testing We have received inquiries such as: - The electrical characteristics of the transformer are unstable - I want to outsource the impregnation process - I want to commission the winding process - I want to produce prototype transformers - I want to create small lot custom transformers If you are having trouble with transformer manufacturing or process support, please feel free to consult with us.
Company information
Akita Trans Manufacturing Co., Ltd. was established in 1966 and is based in Ikawa Town, Akita Prefecture. It is a manufacturer of electronic components, primarily transformers. Despite being a small company, it prides itself on its "integrated production system" and has maintained stable transactions for over 30 years with Tamura Manufacturing, a subsidiary of a major electronics manufacturer. Currently, the company is entering a phase of expanding its sales channels while leveraging the solid technology and trust it has developed over many years. The representative is actively managing both the field operations and the business side, while seeking a system that allows for external sales efforts.
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