How Is a Transformer Constructed?

What is a Transformer?

A transformer is in essence a very large circuit that is required to transfer electricity over long distances. The most common transformers people think of are those connected on power lines. However, even larger models exist in relay stations you might notice on the side of the road from time to time. They are required because electrical wires have an inherent resistance in them. As electricity passes through these wires, the voltage slowly decreases as a result of this. Transformers convert household-use electricity, which is low voltage and high current, into high-voltage and low-current electricity--which travels without losing nearly as much power. Another transformer near the end of the electrical line then converts the electricity back to its original format so it can be used.

How is a Transformer Constructed?

A transformer is a surprisingly simple device to construct. First, the shell is made; some of them look like large cylinders, and others look like large boxes. In the interior hollow of the shell, an oversized circuit with an internal breaker is inserted and soldered into place. The exact nature of the circuit is considered a trade secret and varies from one electrical company to the next. The hollow around the circuit is then filled with several gallons of mineral oil to act as a coolant to keep the circuit from overheating. The top of the transformer has two large cables running through it. The bottoms of the cables are soldered to the leads on the circuits before the top is screwed into place. The transformer is complete; to be functional, the cables leading from the top need to be spliced into a power line.

Are There Dangers Resulting From This Construction?

Many thousands of transformers explode each year across the country when they overheat and the mineral oil they contain ignites. This happens primarily due to power spikes from lightning strikes. This could be prevented if they were constructed using better materials and safety measures. Unfortunately, the construction of transformers is deregulated, so there are no laws or standards that must be met. As a result, they are made from substandard materials with almost no safety measures in mind. Alternate non-flammable coolants exist but are more expensive.