IMP POWERS LIMITED Doc.
No:
PRODUCTION PROCESSES Rev.:R0
Date:
WINDING Page: 1 of 5
MANUFACTURE OF SEMI-CONTINUOUS DISC COILS
1.0 SCOPE
This specification covers the method of manufacturing semi continuous /continuous disc
windings.
2.0 EQUIPMENT
A. Winding machine
B. Conductor tensioning device
C. Reel / Drum stand
D. Winding formers
E. Non-metallic mallets
3.0 PROCESS
3.1.0 GENERAL CONFIGURATION
The coil shall be wound on keyed strips. The number of turns in a disc / section may a
whole number or fraction as given in winding design sheet.
Coil shall be wound with single or multi conductors as per the design sheet and shall be
wound as standard, unless specified, otherwise as non-standard on winding sheet.
The process of winding shall be as per the sequence given in FLOW CHART: and the
various precautions and guidelines shall be observed.
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mohanan thazha ellaparambath
Date :
IMP POWERS LIMITED [Link]:
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3.2.0 ARRANGEMENT OF FORMER INSULATION
Former shall be mounted on winding machine and insulation arranged
The outer diameter of the final cylinder (sacrificial/ stabilized winding cylinder) shall be
1mm to 2mm more than the specified diameter.
Keyed strips duly inserted with keyed blocks shall be arranged and leveled and spot
glued to the cylinder.
Number of keyed strips shall be as per the winding design sheet. Intermediate strips
shall also be arranged if specified in winding design sheet.
In case winding design sheet does not call for intermediate strips, temporary additional
strips shall be provided where in the distance between adjacent keyed strips exceeds
70mm. The segment shall be numbered serially using BLUE WAX PENCIL for easy
reference.
The keyed strips and intermediate strips shall be strapped firmly in position at two
positions, centre and other.
3.3.0 ARRANGEMENT OF CONDUCTORS AND LEAD
The required number of conductor drums shall be loaded on drum stand and the
conductors coiled off.
Conductors shall be passed through the tension block assembly and the start lead shall
be prepared.
3.4.0 STARTING THE WINDING
The winding shall generally be started from top end (i.e. section No.1),. However,
where the winding is done on the stabilized winding cylinder, the start shall be from
bottom end.
APPROVED BY:
[Link] PREPARED BY:
mohanan thazha ellaparambath
Date :
IMP POWERS LIMITED [Link]:
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[Link] STARTING BUILD UP/REVERSE DISC
The operation shall be carried out in the following sequence
(A) Firmly clamp/strap the start lead.
(B) Position the first rider block on the former under the lead and wind first turn over it.
(C) Position the second rider block below the first turn near its completion and wind the
second turn.
(D) Mark the cross over positions, make cross over bends and finish them as specified
in PST-04.
(E) Unclamp the lead, if required and collapse the turn, separating them on the former
surface.
(F) Rearrange the conductor in the required sequence of the specified transposition and
place the reinforcement insulation.
(G) Guide the turns one over other starting from cross overs at bottom and then up
towards till outermost turn and position the section at right angle plane by hand. Turns
may be tied using cotton braid or tape, temporarily while doing this.
(H) Push slide the built up section along the keyed strips to the required position and
re-clamp the start lead.
(I). Tighten the section gradually by applying tension on the conductors and lightly
tapping the outer turn. Insert the radial adjustment, press board packing strips at
required position BEFORE final tightening of the section.
(J) BEFORE final tightening of the section also provide 'U' shaped, 0.8mm thick press
board strip between lead and the first turn, projecting by at least 75mm on either side
of lead. Slide the keyed blocks in position and gently tap the turn from side over the
keyed block position using padded press board rectangular piece.
A 'lead shield' of at least 1.5mm thick press board shall be provided between the first
and 2nd section, at the segment in which the lead is taken out.
The keyed block thickness shall be reduced to that extent in the shield zone.
Sharp edges tools and even insulation items shall not be inserted in the section, once
tightened.
(K) Complete tightening of the section and ensure that the cross overs at bottom and
the start lead have appeared in the correct segment.
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mohanan thazha ellaparambath
Date :
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[Link] WINDING FURTHER SECTIONS
The second section shall be wound over the cross overs coming off the first section, as
a normal/forward test. The specified number of turns shall be wound outwards from the
former.
Radial adjustment packing strips shall be provided at the required position.
Cross overs shall be marked and bends made, in accordance with PST-04. Conductors
of the turns shall be transposed at cross overs as specified and reinforcement insulation
shall be provided as per PST-04.
The section shall be wound tight with tension on conductors and at right angles with
respect to the former plane.
The subsequent sections shall also be wound, alternately as reverse/built up section
and forward/normal section.
[Link] WHEN START LEAD IS FORM I.D. SIDE OF THE COIL.
Start lead shall be clamped/strapped to the former in the required segment and the
specified number of turns shall be wound straight over it.
Radial adjustment packing shall be provided at the required position.
Cross over bends shall be marked and made
Conductors of the turn shall be transposed of cross over as specified and reinforcement
insulation shall be provided
Section following this shall be reverse section and shall be wound in accordance with
clause 3.4.1 detailed earlier.
3.5.0 BANDING AND ANCHORING
The first and last 4 sections of the winding shall be taped tightly together by two layers
of fine polyester tape followed by 2 layers of crepe taper tape, near the lead root and
every quarter perimeter.
In addition, anchoring and banding of leads and sections shall be done.
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3.6.0 TRANSPOSITION
Conductors shall be transposed at every pair of sections.
The type of transposition shall be as specified in the winding design sheet and the
procedure as detailed in PST-04
3.7.0 JOINTING OF CONDUCTORS
Joints shall be made as detailed in PST-10.
3.8.0 FIXING OF [Link], CIRRUGATED
RINGS & SPECIAL INSULATION
Such insulation items shall be fixed while the coil is being wound, at their specified
positions.
D.O.F. washers shall project on I.D./O.D. side sufficiently so as to direct the oil flow
through the radial ducts of the coil.
The D.O.F. washers shall be notched on its I.D. side, if required, to accommodate the
inner cross overs.
Fixing of corrugated angle rings shall be close fitting to the specified discs and without
any undue wrinkles.
A lead shield of at least 1.5mm thick press board shall be fixed between the lead and
the adjacent sections whenever the thickness of keyed block between them is less than
7.0mm. (SKETCH-6).
3.9.0 OTHER OPERATIONS
Radial and axial pack out, finishing and unloading operations shall be as per the norms
and guidelines detailed in PST-03
4.0 INSPECTION AND TESTING
During manufacturing, the coil shall be subjected to inspection and testing to be done.
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