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Journal : rekayasa

Design and Implementation of a Transformer Winding Machine with Buck-Boost Converter-Based DC Motor Drive Muhammad Rizani Rusli; Gigih Prabowo; Taufiqurrahman Taufiqurrahman; Arman Jaya; Syechu Dwitya Nugraha; Era Purwanto
Rekayasa Vol 19, No 1: January - April 2026
Publisher : Universitas Trunodjoyo Madura

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.21107/rekayasa.v19i1.27486

Abstract

This research presents the design and implementation of a high-frequency transformer winding machine driven by a DC motor with a Buck-Boost converter to produce transformers accurately and efficiently. The system integrates a DC motor controlled by a Buck-Boost converter, which regulates the voltage to the motor, ensuring stable performance during the winding process. The winding machine design includes a stable mechanical platform, a V-belt mechanism for power transmission, and optocoupler sensors for real-time monitoring of winding turns. The Buck-Boost converter stabilizes voltage fluctuations, allowing smooth motor operation under various input conditions, thereby improving machine efficiency and reliability. Experimental tests on the rectifier, Buck-Boost converter, and DC motor demonstrate high efficiency and stable performance, with minimal deviation between calculated and experimental results. Test results show that this machine can perform precise winding across different duty cycles, with optimal speed control and stable operation. Compared to existing transformer winding machines using induction motors or stepper motors, this system offers better control, faster winding speeds, and greater adaptability to different production conditions. The developed machine significantly contributes to industries such as transformer manufacturing and power electronics, with increased productivity, reduced production costs, and improved transformer quality, especially in high-frequency applications such as renewable energy systems and electric vehicle charging.
Co-Authors -, Irianto -, Suryono -, Sutedjo Abdillah Aziz Muntashir Achmat Ridwan Nudin Agusalim, Imam Dui Ahmad Firyal Adila Akmal Fikri Akmal Fikri Arman Jaya Arman Jaya Aulia Rahma Annisa Dadet Pramadihanto Diah Septi Yanaratri Dui Agusalim, Imam Eka Prasetyono, Eka Eko Hadi Suharyanto, Hendik Eko Henfri Binugroho Endro Wahjono Endro Wahjono, Endro Epyk Sunarno Era Purwanto Evi Nafiatus Sholikhah Farid Dwi Murdianto Ferdiansyah, Indra Gigih Prabowo Gilang Rizki Saputra Gumilang Samino, Rangga Yoga Habibi, Muhammad Nizar Handri Toar Hartono, Helleina Rejeki Putri Hary Oktavianto Hendik Eko H Suharyanto Himmawan Sabda Maulana Imam Dui Agusalim Indhana Sudiharto Ircham Badrus Rahmadani Irianto Irianto Jaya, Arma Jaya, Arma Lucky Pradigta Setiya Raharja Lucky Pradigta Setiya Raharja Luki Septya Mahendra Luki Septya Mahendra Mentari Putri Jati Mentari Putri Jati Mentari Putri Jati MOCHAMAD ARI BAGUS NUGROHO Mohammad Zaenal Efendi Naufal Fadhlirahman Dheningrat Nugraha, Syechu Dwitya Nugroho, Mochammad Ari Bagus Ony Asrarul Qudsi Praharsena, Bayu Praharsena, Bayu Prilian Eviningsih, Rachma Purawanto, Era Qudsi, Ony Asrarul Rachma Prilian Eviningsih Rachma Prilian Eviningsih Rachma Prilian Eviningsih, Rachma Prilian Raden Sanggar Dewanto Rakhmawati, Renny Ridwan Ridwan Risyda Zakiyah Hanim Sanggar Dewanto, Raden Saputra, Gilang Rizki Satria, Novian Fajar Septi Yanaratri, Diah Setiya Raharja, Lucky Pradigta Suharyanto, Hendik Eko Hadi Sulis Wanto Suryono Suryono Sutedjo Sutedjo Taufiqurrahman Taufiqurrahman Teguh Hady Ariwibowo wk, Ridwan wk, Ridwan Yakin, Ainul Yanaratri, Diah Septi