Streamlining Transport Costs
for Linear Transformer Manufacturers
Innovative solutions that reduce volume, enhance efficiency, and lower transportation costs.
Industry Focus:
Linear Transformer Manufacturers
Client Challenge:
The client utilizes whole-extruded nylon bobbins for the assembly of their transformers. While this extrusion method is recognized as industry best practice for producing sturdy and structurally sound bobbins, the inherent lightweight and large volume of these components result in significantly high freight costs. This inefficiency in shipping low cost items overseas impacts the overall cost-effectiveness of their transformer manufacturing process.
Project Timeline:
2024
Execution Timeframe:
3 weeks
Solution Provided
To address the client’s problem, we drew inspiration from assembly bobbins and developed three specialized molding tools for producing the parts of the nylon bobbin, namely:
- The Flange
- The Stack
- The Common Piece
These parts were manufactured separately and then assembled in a manner consistent with the traditional Paper Laminate and Glass Epoxy Bobbins.
Opportunity - Unique Engineering
Prior to Nylon Bobbins, assembly bobbins assembled from pressed components were common. These bobbins were designed to be assembled on-site, which enabled them to be transported flat, thereby significantly reducing their volume during transit.
The tooling required to make nylon bobbins are relatively expensive and time consuming to develop (based on size) and when the transformer designed is not of a standard size it isn’t economical to create a tool for an odd sized bobbin. To overcome this, our concept of creating assemblable Nylon bobbins provides us with avenues to save on tool costs. A simple tool with interchangeable cavity plates is used to mould the 3 types of parts – 2 of each. An added advantage is that some of the parts can be reused for other bobbin sizes.
The result?
Transformer manufacturers might be obligated to choose other bobbin materials over nylon bobbins due to the unavailability of relevant sized Nylon Bobbins. This invention allows for a cost effective way to manufacture the Nylon Bobbin. The volume of a single piece nylon bobbin is high when compared to the piece part design thus saving a lot of space during transportation. This in turn results in huge savings in packing costs and fuel costs. Assemble-able Nylon Bobbins are designed to accommodate various sizes and types of wire windings, allowing for customization based on specific transformer requirements. This flexibility ensures optimal space utilization and efficient winding processes.