Production of Audio Transformers
Transformers are one of the products that you have to buy on trust,
like the "famous pig in a poke." You can´t look inside, and you have to
depend on the manufacturer to build it well. However, attention to
detail is essential, particularly in output transformers, where the
performance of the transformer depends strongly on the careful winding
of each layer, so that each turn is lying next to each other without
crossing over or leaving a gap.
This carefully done but time-consuming winding approach has the
advantage that each layer has a fixed number of turns. For this reason,
every transformer sample of the same model sounds just like every other
sample. This is as opposed to earlier production on multiwinder
machines, where it was impossible to have closely supervise, for
example, ten transformers wound at the same time.
For me, it is
not only very important to count the turns and measure up the thickness
of the wire used for reproducing old transformers, but also very close
attention is paid to the thickness and the dielectric strength of the insulation materials.
Take a close look at the picture to the right (by clicking on it) to
see the varying thickness of paper insulation used.For transformers that were originally wound on paper bobbins, I´m using paper bobbins too, because in most cases the end transformer will have a different stacking height as compared to one using SRPB or plastic bobbins. A different stacking height will change the whole mean turn length of the transformer and therefore all electrical parameters as well.
After all components are fitted, the whole coil looks like it was
"painted on." All wires coming out of the coil are insulated with a
teflon sleeve to prevent short circuits.These pictures were made to let you know exactly the level of
craftsmanship you are buying. This kind of winding takes a lot of time
and therefore my transformers are not inexpensive, but keep in mind,
how many manufacturers let have you such a close look inside their
transformers?