Jan 2025 – Feb 2025
What?
Designed a custom jig to assist production workers in wrapping wire around transformer cores accurately and efficiently
How?
- Designed a jig that elevates and secures the core, enabling smooth wire threading from both the top and bottom
- Integrated a telescopic end holder to anchor wire at a precise distance for consistent length control
- Iterated on multiple prototypes to resolve issues with holder stability and fork height
- Added adjustable levelers to accommodate multiple core sizes
- Fabricated components using 3D-printed PLA, repurposed materials, and scrap wood to minimize cost
Result
- Reduced wrapping time from 20 minutes to 15 minutes per unit
- Improved repeatability and ease of use for production workers
- Enhanced workflow efficiency for a time-sensitive transformer order
Nolan Phuong 