Brand: Pahsa Enerji
Transformer Clamping Bar Manufacturing Process
A transformer clamping bar is a critical structural element that increases mechanical strength and reduces vibration by securing the transformer's magnetic core. High strength, dimensional precision, and ease of assembly are key criteria in the production of this part.
1. Design and Engineering
The production process begins with the customer's transformer core dimensions, clamping force values, and connection types. Modeling is performed in a 3D CAD environment, and material thicknesses, bolt hole locations, and mounting clearances are determined.
The necessary strength calculations are performed, and the appropriate material is selected to prevent deformation during clamping.
2. Material Selection and Cutting
Steel grades such as St37, St44, or S235JR are typically used. Steel sheets or profiles are cut to precise dimensions using CNC plasma/laser cutting machines.
After cutting, the parts are ground or deburred to ensure a smooth surface and accurate dimensional tolerances.
3. Bending and Shaping
If necessary, the parts are bent to the desired angle and form using hydraulic press brakes. This step is crucial for ensuring the complete fit of the iron to the transformer housing.
4. Welding and Joining Processes
The cut and shaped parts are joined using MIG/MAG or TIG welding methods in accordance with the design.
After welding, the surface is cleaned, and alignment is verified through dimensional checks.
5. Drilling and Tapping
The connection holes for the clamping bolts are machined on CNC drilling machines. Tapping is performed in the required areas. All holes must be axially accurate in accordance with the standards.
6. Surface Cleaning and Protection
After welding and machining, the clamping bars are sandblasted (SA 2.5 standard). An industrial primer, top coat of paint, or galvanized coating is applied to ensure long-term corrosion protection.
7. Quality Control and Assembly Testing
In the final stage, products are subjected to inspections of dimensions, weld quality, and surface finish. A mock assembly is performed upon customer request to ensure the bolt holes and mounting surfaces fit perfectly.
8. Packaging and Shipping
Approved products are packaged in protective packaging to prevent deformation during transport, labeled, and prepared for shipment.