Fine process and key considerations for insulation treatment of control transformers

In the manufacturing process of power equipment, insulation treatment is one of the key links to ensure the safe and stable operation of equipment. Especially for core components such as control transformers, the fineness of its insulation treatment directly affects the reliability and safety of the entire power system. The two core steps of coating insulating varnish and coating insulating paper in the insulation treatment of control transformers will be used as the starting point to explore its process requirements and key considerations in depth.

Precise operation of coating insulating varnish
In the insulation treatment of control transformers, coating insulating varnish is a crucial process. The coating quality of insulating varnish is directly related to the electrical isolation effect between windings and the overall insulation strength of the transformer. Therefore, the following points need to be strictly controlled during the coating process:
Coating thickness control: When applying insulating varnish, the coating thickness must be uniform. Too thick a coating may cause poor heat dissipation and affect the operating efficiency of the transformer; while too thin a coating may not provide sufficient insulation strength and increase the risk of electric shock and short circuit. Therefore, the thickness of the coating needs to be accurately calculated and controlled according to the performance of the insulating varnish and the specific requirements of the winding.
Coating quality inspection: After the coating is completed, the coating quality needs to be fully inspected. The inspection content includes whether the coating is uniform and smooth, and whether there are defects such as bubbles and cracks. For any problems found, they should be repaired or re-coated in time to ensure that the insulation effect meets the design requirements.

In addition to coating with insulating paint, coating with insulating paper is also an important part of controlling the insulation treatment of transformers. As a physical barrier, insulating paper can further improve the electrical isolation effect between windings and protect the windings from erosion by the external environment. During the coating process, the following points should be noted:
Tight fit and wrinkle-free: The insulating paper needs to fit tightly with the winding to ensure that there are no wrinkles or gaps. Wrinkles and gaps will reduce the insulation effect and increase the risk of leakage and short circuit. Therefore, careful operation is required during the coating process to ensure that the paper is flat and tightly wrapped on the winding.
Multi-layer coating and inter-layer treatment: For windings that require multi-layer coating, attention should also be paid to the treatment between layers. Each layer of insulating paper should ensure no overlap or misalignment, and appropriate pressure should be applied to remove air and excess adhesive. This can not only improve the insulation effect, but also enhance the overall mechanical strength of the winding.

The insulation treatment of the control transformer is a complex and delicate process, involving precise operation and strict control of multiple links. When applying insulating varnish and coating insulating paper, it is necessary to fully consider factors such as the performance of the insulating material, the specific requirements of the winding, and the operating environment of the power system. Through fine process operation and strict quality control, it can ensure that the control transformer has excellent insulation performance and stable operating characteristics, providing strong guarantee for the safe and reliable operation of the power system.

The insulation treatment of the control transformer is not only an important link in the manufacturing process, but also one of the key factors to ensure the safe and stable operation of the equipment. In the future manufacturing process, we should continue to optimize the insulation treatment process and improve product quality and reliability to meet the growing needs of the power system.