How are transformer windings and transformer taps manufactured?

Question

I know a good bit about transformers from a theoretical perspective, but how are the windings made? What kind of insulation is used on the wire? How is the number of coils accurately counted? How are the taps accurately placed?

I guess this could apply to any wire winding as well, like in motors/generators.

Thanks!

A good reference would be helpful since I have been having trouble finding good info on the subject of winding manufacturing.

Answer 1

They use automatic coil winding machines to provide the correct number of turns, spacing and tightness of the wraps.

Coils and frames are inserted into the winding machines and they wrap the wire like you would a spool of sewing thread.

The wire used is copper wire with a polymer coating as insulation. In the old days, used to be lacquer-based, but I'm not sure what is used today.

Search for transformer, winding, coil machines automatic. You might find some online magazines that list advertisers.

Answer 2

This topic can go on and on. Square wire is often used to get the windings closer together and get the most efficient use of space. Efficiency is also increased using high reluctance core material. Taps are placed by bringing a connection out to a terminal at a given number of windings. Since the input and output voltages are based on the ratio of primary to secondary windings, the taps are placed at the number of windings required to obtain the correct ratio of turns to produce the desired voltage.

Answer 3

Just adding to above:
The taps are made by stopping the winding after a certain numb er of turns, the wire is pulled "out" of the frame and soldered to the tap, then put back in to continue the winding.

Answer 4

they put sheets of iron together to make the core.then start winding.there is a thin layer of insulation between wires.