Pole Transformer Fabrication
Why Electrical Engineering Stack Exchange recommends it
Electronics Stack Exchange users link it when they want to show how real pole transformers are wound and assembled, for example the wide foil low-voltage winding and the CRGO core.
Recommended by 3 people across 3 different months, 2014 to 2019.
What it is
A five-minute factory walkthrough, taken from the How It's Made series, showing how pole-mounted electrical power transformers are built. It covers winding the coils, stacking the grain-oriented steel core and assembling the finished unit. It is a short narrated manufacturing clip re-uploaded by Steve McCollum.
What people said
Recommends Adam Davis · 2014-06 · Electrical Engineering Stack Exchange · on “Transmission lines in USA, household transformers - efficiency and economy”
A typical cylindrical pole transformer is 25-75kVA, handling between 1 and 3 homes (100A 240V service each). You can get pole mount transformers up to 500kVA. Pad mount transformers can be much, much larger. For those interested in how pole mount transformers are constructed, here's a video of the assembly process: [this video]
Recommends jonk · 2017-01 · Electrical Engineering Stack Exchange · on “Can off-line SMPS magnetics be used for wideband isolation of power line waveform measurements?”
Since you bring it up... worth also looking up metglas.com and AMT/AMDT transformer technology. Also, a nifty video on pole transformer manufacturing using CRGO: [this video]
Recommends Dave Tweed · 2019-10 · Electrical Engineering Stack Exchange · on “Approximation of the resistance in a solenoid consisting of alternating sheets”
You should consider winding the other way, with the metal sheet parallel to the solenoid axis rather than perpendicular to it, like the low-voltage winding on a pole transformer, as shown in this video [this video] .
Cites sharptooth · 2015-05 · Electrical Engineering Stack Exchange · on “What's the thick wide aluminum tape used for in last mile grid transformers?”
This YT video (scrolled to 0:45) [this video] shows the process of fabricating a pole mount transformer. At 0:45 the following is shown: there's a wooden brick used to hold everything together, it's covered in cardboard and then the person starts winding wide thick aluminum tape onto this brick. Aluminum tape is as wide as the brick, so the brick is effectively wrapped into multiple layers of that tape. Adjacent layers are separated with thick insulating paper. The core is fabricated much later, so it's not the core. What's that tape for? It's thick so I'd guess it's the secondary winding (low voltage, high current, lots of heat) but then why is it closest to the transformer center where it's har