For Transformer & Coil Manufacturers
About Vasavi VLCRTZ
VLCRTZ
is specially designed for transformer and coil manufacturers and users.
Study this write-up before buying LCR meter.
1. Transformation ratio:
For transformers the transformation ratio is more important
parameter than inductance. You might be testing only inductance
values . With VLRTZ you can test the transformation ratio and
winding phase in addition to inductance values.
2. Bifilar windings: Bifilar windings
are meant for perfect coupling. The only test for the bifilar winding is
the transformation ratio and not the inductance value. But you might
be testing inductance only and satisfying with it. By testing
inductance you can not guarantee the bifilar winding. The only and the best
test is transformation ratio which assures the coupling.
3. Turns testing: The main
process of the transformer manufacturer is to wind the bobbin or coil.
Turns or TR test is the main process test for winders. For coils
and transformers with closed cores; the Inductance will not guarantee
the turns. The closed cores can not give precise AL values. The inductance
values must be given with a wide range. Presume that the core has +30% AL
value and number of turns were accidentally put with -15%. With these conditions
the transformer is accepted without expected performance. Once you
define the core and number of turns, you have no control over the inductance
value. Testing the number of turns of the bobbin is very important.
VLCTZ can be upgraded for turns testing apart from other existing parameters
by attaching TURNS TEST PLATFORM. Otherwise the transformation ratio test
in addition to inductance value would guarantee the required transformer
function.
4. Centre tap: Centre tapping
is a regular requirement for the transformer manufacturers. Instead of taking
the tapping at the time of winding; it is a common practice to either
wind as a bifilar or wind separately and then join them in series.
In a bobbin with multiple windings locating the start and finish may not
be possible by visual checking. So you have to make some way of cross checking
the start and finish of the windings to make the terminations properly.
One way is to put the windings in series and check the inductance and thus
locate the start finish and terminate. The best way is to check
the transformation ratio. When you are testing the transformation ratio with
VLCRTZ you are locating the start finish and also cross checking
the transformation ratio.
5. Test Conditions: To understand
test conditions let us consider the following case. A transformer
manufacturer carefully tests and supplies to the buyer. The buyer rejects
the transformers saying that the inductance values are not within
limits. The vendor tests them again in his instrument and finds the values
well with in the limits. His instrument is showing correctly
with some other coils. But where is the problem? There must be some scientific
reason. The most possible reason could be in the specification itself. Some
absent minded engineer designs and closes the drawing ignoring
some important specifications.
The value of an inductor depends more on the conditions of measurement.
This is particularly true for iron core (ferrite also) inductors for
which measurement repeatability with in a few percent is considered good
and is usually adequate. Most of the higher value inductors are iron cored
(ferrite or laminated cored). Iron core inductors are non linear and therefore
the measured inductance depends on the level of the test signal, test frequency,
measurement mode etc. Inductance value without giving the test conditions
is incomplete specification. Many designers give the test frequency. Some
even give series or parallel equivalent value. But many ignore the
test voltage. Some of the designers use hit and trial method. They design
the transformer, it works. To make the specs, they measure the
inductance values on the available instrument say; XYZ. May
be this instrument is set to measure at 1.0 Vrms by default. When the vendor
measures the same transformer with the available ABC LCR meter, it
is showing a different value. Could be in ABC LCR meter the test voltage
is 0.3 V. Can we say that XYZ is good and ABC is bad. Both may be good. Only
the difference could be the test voltage.Vasavi's VLCRTZ comes with
the variable test voltage and variable test frequency. Verify the
specs. These specs may or may not be sufficient for all the conditions.
No single instrument can meet all requirements.
6. Simultaneous display of Q factor:
For some of the coils the Q factor is more important than the inductance
value. For high inductance coils like CT's, the Q factor will
indicate the health of the coil. Irrespective of whether specified or not,
the manufacturer must make his own specs for Q factor based on his experience
of the coils and tests. Vasavi's VLCRTZ is provided with two displays, one
for L value and the other for Q indication simultaneously. Let
us study the example of the ferrite CTs with large number of turns.
Suppose 1 to 2 adjacent tuns are shorted in the process. Can you check by
testing resistance? Or inductance? 2 turns short in 5000 turns.Now
verify the inductance value. You will not find any difference in L value.
The difference is negligible. Then how do you find such a short? Observe
the Q value with and with out shorting. You will be surprised
to see that the Q factor reduces by a large extent. Thus you
will be able to catch such usual winding defects while testing L value
alongwith Q factor. Now you may agree why you need simultaneous display
of Q factor.
7. DC resistance Test: For
transformer people the resistance means DC resistance. Most of the LCR meters
come with AC resistance test. For non inductive resistors there is no problem.
But for coils and transformers the windings have large reactance in series
with the resistance. So the AC resistance measurement will be totally different
from the DC resistance values. LCRTZ has both AC resistance and DC resistance
tests.
8. Impedance matching transformers:
The very name indicates the importance of impedance measurement. The
telecom transformers are specified to test impedance along with other parameters.
For these types of coils and transformers, the impedance is the main parameter
but the inductance and resistance are the subsidiary parameters.
As the transformer and coil manufacturers use LCR meters without this test;
the end users ignore or avoid giving this test to the manufacturers.
With Vasavi's LCRTZ You can check the impedance at different test
frequencies and test voltages.
9. RS232C Control of LCRTZ
from PC (Option):
Let us imagine the usual method. Test with LCR meter, note down the
readings, type the readings into the computer and then take the report.
Each job is done by a different person. There can be error at each
stage. While reading, the technician may make error. The operator's
mind is recorded like a hard copy with the pass results and there is every
chance of missing the rarely observed fail readings. Apart from reading
, the operator has to judge whether the readings fall with in the
limits or not. When he records, he may write 3 as 8, the recording
error. Now these values are to be typed. Can not you have typing error?
Finally what is the result? A mess of mistakes and human errors.
The entire exercise is for name sake only.
Now let us study the alternative. Imagine VLCRTZ with RS232C control.
The limits along with test conditions are carefully set by a
more experienced engineer once for all and stored in a file.
To test the transformer, the operator has to load the file and connect the
transformer to jig or connectors. Any unskilled person can do the handling
work. The PC saves the test results into a database table, which you
can use for taking reports or analysing the results. The operators efficiency
will increase as he has not to strain his mind. Speed is increased
without loosing quality. Is this not a better choice?
10. System with 20 pin scanner :
For multi pin transformers you can consider Vasavi's CVCT-S20 an automatic
test system with scanning facility. This system is very
ideal for testing SMALL TRANSFORMERS like SMPS transformers,
Telecom transformers (HYBRID, POT CORE, RM-CORE), Pulse transformers etc.
The testing will be very fast and fool proof. The
system scans at one stroke, all the windings of
a transformer .
11. System without scanning facility:
Even without having a scanner, you can have the luxury of transformer testing
automatically. The operator's job is to make the connections only.
He need not worry about readings. Instead of a scanner selecting the
pins automatically, the operator is doing that job. But his burden of noting
and judging the reading is totally removed. The system consolidates
all the defined tests , displays the tested results and also
prompts you Go or No Go based on limits entered for each parameter. Further
you can also save the data in to a database table.
12.Testing on sampling basis:
This is a notion by the inward inspection and QC departments.
Yes, they are right for capacitors, resistors or semiconductors; because,
the manufacturing is done by automatic machines. Further the process lines
also include 100% testing in the production chain itself. In the case of
transformers and coils, they are generally manufactured by semiskilled
labour and are being handled by small manufacturers without having proper
environment. So 100% must be tested both at the manufacturer
and the end user. The notion of sample testing should not be applied
for transformers and coils.
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