unlimitedprojects.com: Aluminium Foil Transformers

Unlimitedprojects.com

A brief profile on Aluminium Foil Transformers

INTRODUCTION

The technology providers are manufacturers of Power Conditioning equipment and Instrumentation and Control equipment for energy management. Their products are marketed under their brand name and enjoy market leadership with a market share of over 30 % in Southern and Western India. This position of market leadership has been enabled by providing greater value to the customer through accent on Value engineering resulting in better quality and reliability at a lower cost.

One of the major impact areas of Value engineering is in the use of Aluminium foil wound transformers. As our power conditioning range of products had a high copper content, the possibility of reducing our dependence on copper due to its relative high cost and price instability was considered. This resulted in our using Aluminium foil wound transformers in place of copper wire wound ones.

The Aluminium foil wound transformers so developed have been successfully used in Stabilisers and Isolation transformers and are working on the field since 1992. As this manufacture involves a convenient and efficient method of winding the foil around the core, they designed and developed the Special purpose foil-winding machine. They now offer this Special purpose foil-winding machine to you along with the know-how to design and develop Aluminium foil wound transformers.

A detailed note on the technology, the winding machine and proposal is given below:

1. ADVANTAGES OF ALUMINIUM FOIL WOUND TRANSFORMERS

COMMERCIAL ADVANTAGES

o Reduced material costs o Stable material costs o Competitive price o Higher productivity of transformers handling larger currents o Savings on freight and packaging

TECHNICAL ADVANTAGES

o Compact size and reduced weight o Increased thermal stability and higher short-term over load capacity o Increased thermal stability and higher short-term over load capacity o Higher surge withstanding capability o Enhanced ability to withstand short circuit currents o Reduced impact of harmonics and high frequency on the design of transformers o Greater insulation reliability

MATERIAL COST COMPARISON

ENAMELLED COPPER WIRE WOUND TRANSFORMER 500 VA 1000 VA 5000 VA PRIMARY SWG 19 17 10 WEIGHT ( Grams) 742 1099 3958 COST ( Rs per Kg) Rs.193.07 Rs.191.97 Rs.l96.35 SECONDARY SWG 17 14 8 WEIGHT ( Grams) 770 1072 3982 COST ( Rs per Kg) Rs.191.97 Rs.l91.43 Rs.201.82 TOTAL MATERIAL COST Rs.291.07 Rs.416.19 Rs.1,580.78

ALUMINIUM FOIL WOUND 500 VA 1000 VA 5000 VA PRIMARY THICKNESS ( microns ) 20 40 140 WEIGHT ( Grams) 398 566 2540 COST ( Rs per Kg) Rs.209.30 Rs.200.93 Rs.l78.20 SECONDARY THICKNESS ( microns ) 40 75 100/150 WEIGHT ( Grams) 396 528 2110 COST ( Rs per Kg) Rs.200.93 Rs.l87.25 Rs.l78.20 INSULATION FILM WEIGHT ( Grams) 166 119 231 COST ( Rs per Kg) Rs.154.07 Rs.154.07 Rs.154.07 TOTAL MATERIAL COST Rs. 188.44 Rs.230.93 Rs.864.23 SAVINGS GENERATED Rs.102.63 Rs.l85.26 Rs.716.55 % REDUCTION 35 45 45

Financials

Cost of the project				  Rs. in Lakhs			
											
											
Cost of Building	Rental 1000 Sq.feet		0.00				
											
Indigenous Equipment					6.70				
											
Preliminary & Pre-operative Expenses			0.10				
											
Provision for Contingencies				1.76					
						Total	8.56
											
					
											
Promoter's equity					3.50				
											
Bank/FI							5.06
				
						Total	8.56				
											
Working Capital requirement from Bank		       12.24				
											

PROFITABILITY										
											
Installed Capacity					12000 Nos.						
Utilised					90%	10800 Nos.																
Selling Price (1000VA)	Rs.400/= each		(A)     43.2 Lakhs			
											
Cost of production

Raw Material	Rs.250/= per pc				27.0 Lakhs			
Labour							 0.5   "			
Utilities						 7.0   "			
Rental							 1.2				
Depreciation						 0.66				
											
Total Cost of Production              		(B)	36.36							
Gross profit 					(A-B)    6.84 Lakhs