Pole Transformer Fabrication Video

This shows how pole-mounted electrical power transformers are made. From How It's Made.

@Sillyzombie666 ...
@Sillyzombie666 No! ? It's ROBOTS BAKING PIES!

about the price... ...
about the price... thats why they use the thick >>aluminium<< strip on the secondary. If they use copper instead, the price will probably skyrocket.. They still? use the copper wire on primary though.

Wait... Is? that ...
Wait... Is? that aluminum strip the secondary coil?

@yourTIV0? It ...
@yourTIV0? It wouldn't be "insanely" expensive. It would be more expensive, sure. However, the cost recovery time is short. Upgrading from Al windings to Cu has a typical repayment time of between 2 and 4 years, due to lower losses, unless the transformer is very lightly loaded. Similarly, for the use of amorphous metal rather than cold-rolled silicon steel, the payback time is also around 4 years.

@ChumpusRex ...
@ChumpusRex Actually, Aluminum is a superb conductor for this application. Using solid copper in place of the aluminum would be insanely expensive, and aluminum is a quite decent conductor. In fact, the main lines going in? to the load centers of many homes and businesses are aluminum (or copper plated aluminum), anywhere from 3 to 4/0 AWG.

f**k, those thing ...
f**k, those thing are made? so cheap! aluminum, WTF people!!

@ChumpusRex ...
@ChumpusRex Actually, the magnetic field outside the cross section of the core is very tiny, so the flux cutting the cross section of the sheets is almost zero, so there? are essentially no eddy currents in the aluminium sheets. The use of steel cores is ideal, we have to consider cost of materials here, ease of fabrication etc. Even though Al. has a higher resistivity, we can compensate by making the conductors larger, hence the sheets. A modern large power transformer is easily 99% efficient

that what I NEED ...
that what I NEED for my amp? !!!

Disappointing that ...
Disappointing that people are? still making transformer with aluminium sheets. Al is a relatively poor conductor compared to Cu, so increases winding losses. The use of sheets is also sub-optimal, as the large conductor cross-sectional area leads to large eddy current losses (part of the core losses). Finally, on such distribution transformers, the use of steel cores is also not ideal, and the use of metallic glass cores gives much better performance and lower operating costs.

I was at this ...
I was at this facility yesterday. It is Power Partners now, not ABB. It was amazing. 650,000+ thousand feet of manufacturing.? Up to 900 of those pole mount transformers a day. They just need to start manufacturing BIOTEMP (or FR3) and they would be king!

When the assembly ...
When the assembly is baked and the glues sets, the winding are bonded together achieving very high strength. This is important, because in power distribution systems the amount of power and prospective fault current is typically thousands to tens of thousands of amps, if a short circuit appears on the secondary? of a transformer the magnetic forces applied on the windings within the transformer can physically rip the windings apart. So the high strength glue stops this from happening.

@rsp196607 Yes ...
@rsp196607 Yes it's hard to see in the video but yes the 3 bus bar aluminium secondary leads do in fact emanate from 3 different locations 1 at each end? of the winding and one in the center. It's a center tapped secondary probably 120v -0-120v. I've been folding and soldering my secondary connections and YES you can solder aluminium together! need aluminum solder. When its baked the glue bonds the windings and the aluminium sheet bus bar connections together, so they don't rattle loose.

@bjtaudio Using ...
@bjtaudio Using mineral Oil is king too as it not only drastically increases the insulation capabilities, but also acts as a cooling system, massively increasing the amount of power the windings can dissipate before overheating compared with dry types. The only down side to it? is if the transformer overheats or the oil ignites from an internal flash-over, the sudden and massive increase of pressure can rupture the outer metal tank, with dangerous explosive killer force. ouch!

This is small ...
This is small single phase primary to split phase secondary may be 25KVA@2% . This video has been handy and now I use aluminium sheet coil for my low voltage secondaries as? it way cheaper than copper. The core steel sheet material that ABB are using is a high quality material that can run at a high flux levels like 1.5 Teslas with very low core power loss, meaning you get more volts per turn, so less turns of wire are needed, better regulation.

@rsp196607 The? ...
@rsp196607 The? aluminium IS the busbar.

This doesn't show ...
This doesn't show the process of? bonding the bus bars to the aluminum strip. Perhaps it's proprietary or uninteresting. If the secondary is 3-wire, center-tapped, then there must be three bus bars bonded to the aluminum strip at different locations, one at each end, and one in the middle. Three bus bars do indeed emanate from the secondary, But it's hard to see that they emanate from different locations on the aluminum strip.

Great video, thnx ...
Great video, thnx for uploading. That is some heavy stuff that they are building. First you think that you can lift the thing easily but then you see that there is a lot of wiring and steel coming up and the finished transformer is very heavy now. In Holland we don't use transformers like? these but we use a small transformer building that will send the electricity to a couple of houses and trough underground wires.

coool i want to ...
coool i want to make one? alone

I use to work in ...
I use to work in the industrial power field (mainly reclosers) and have serviced several transformers. I've never seen thermoplastic busings on a transformer before. I'm fairly? certain the the busings seen in this video were ceramic bushings, at least the primary was, couldn't see the secondaries very well.

check my? videos ...
check my? videos for some real high voltage transformers

You can buy a ...
You can buy a refurbished or new single-phase pylon transformer for around $1200 - $30,000 depends on size.? Companies that sell them is Alfa transformer or Temco transformer.

Let's get some ...
Let's get some Moloney stuff? in here.

@metermatch not ...
@metermatch not even talking? about GSU Monsters price tag :))))))

@SmashCOBamberg ...
@SmashCOBamberg Actually those are small split-phase transformers and not that expensive. If you want some big and expensive stuff look for step-up or step-down? substation transformers.

his job would be my ...
his job would be my hell.?

cool, always wanted ...
cool, always wanted to? know how those things we made.

@SmashCOBamberg A ...
@SmashCOBamberg A 160? MVA power transformer at a receiving station, 230kv to 34.5 kv costs about 5 million dollars.

To the "Average ...
To the "Average person" i could use the raw power for? one hell of a Tesla coil!!! ;)

I am thinking that ...
I am thinking that the fault detector is actually across a few windings of the? primary near the ground side.