The
following equipment is used to produce High Current Powerline Filters.
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Coil
Winder - Sold
The coil winder above will take the copper
strip, apply great pressure,
and form a single layer helical edge wound
winding. This precision
operation includes exact turns count and
automatic cutoff which virtually
eliminates all scrap at this stage.
Close-up view of winding head, feed
mechanism, and cutoff slide.
Tab
Puller - Sold
The puller performs a secondary operation
on each individual winding by
straightening the last section of each end
and extending it. At a later
stage, these extensions will be formed into
crimping tabs for the round
interconnecting wires of the filter.
Encapsulation Fixtures –
Sold
The winding along with insulators are
assembled on to fixtures which will
clamp everything tight and hold position
during the encapsulation process.
There are approximately 270 fixture sets.
Estimated replacement cost –
$21,600
Vacuum Tanks – Sold
The fixtured windings are vacuumed
impregnated in epoxy resin using one of
two heated vacuum tanks.
The epoxy impregnated windings are heat cured
in large batches using this
oven.
After the curing cycle, the windings are
extracted off of the
encapsulation fixtures.
The final step is to cut the tabs to length,
clean the cut ends of the
epoxy coating, and form the soldering tab for
attaching interconnect
wires. The trimming and forming dies are
positioned on either side of the
sandblast cabinet to provide a continuous
work flow.
The sandblasting operation consists of three
pieces. The actual sand blast
cabinet (center of left picture ) contains
the blasting nozzles, the sand
separator (right side of left picture), and
an air recycler
(right picture). The air recycler saves considerable
energy costs by
eliminating the loss of conditioned air in
the work place.
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The terminal assembly used in the powerline
filters consists of heavy
gauge round wires, used for internal
connections, which are crimped and
soldered to a threaded stud terminal. The
terminal press which crimps the
parts has several die sets to accommodate
different terminal / wire
combinations.
The soldering machine will solder the crimped
terminal to provide a very
low resistance connection. Once the terminal
/ wire is loaded, it is
pneumatically clamped, heated, automatically
fed solder, and re-heated to
properly flow the solder under computer
control. The heating head is water
cooled for continuous usage.
After assembly of the filter and prior to
potting, the filter is preheated
in this oven to minimize the thermal stress
on the components when the hot
potting compound is poured in.
The 100 gallon potting tank has separate
heaters and controls for both the
main tank and the pouring nozzle. The slow
speed agitator continuously
mixes the contents to provide a homogenous
compound.
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