Implementation Of An Automated Transformer Rewinding System

Transformer rewinding is generally a manual process that depends on skilled operators and predefined winding data, which may result in calculation errors and increased rewinding time. This project presents a bobbin-based automated transformer rewinding system using a microcontroller to improve accuracy and efficiency. The system accepts basic electrical inputs such as input voltage, output voltage, required output current and bobbin dimensions. Based on these inputs, the required number of winding turns is calculated using empirical transformer winding rules and an appropriate copper wire gauge is selected using the current density method. The system also verifies whether the winding can physically fit within the given bobbin dimensions by calculating turns per layer and total winding thickness. An Arduino UNO R4 controls an induction motor through a relay module, while a rotary encoder provides accurate turn counting. The calculated parameters and winding status are displayed on an LCD. This system reduces human dependency, minimizes errors and provides a cost-effective solution for transformer rewinding applications.