Transformer production
The architecture and layout of a modern workshop is the creation of a complex engineering ecosystem. A modern workshop consists of strictly delimited zones, each responsible for a key stage of a transformer's "birth":
Tank and Cover Fabrication, Welding, and Core Assembly Workshop
Metal Structures Section
The fabrication of tanks and covers requires stands, calenders, a bending machine and guillotine shears, a stamping press, plasma, a laser machine, a punching press, saws, but the main machine is the Corrugated Panel Production Line.
Magnetic Core Section
This section features machines for longitudinal and transverse cutting of electrical steel, as well as core assembly tables.
Welding Section
This section speaks for itself: all welding equipment, with the "engine" of this section being the shot-blasting unit. Surface preparation requires special attention to guarantee painting quality throughout the life of the transformers (20 years and more). Shot-blasting units are divided into turbine and pneumatic types depending on the dimensions of the parts. This phase is carried out before painting the transformer tanks.
Painting Section
Depending on productivity, painting lines can be powder, flow coating, or dipping, but the initial phase for all types is the pre-treatment tunnel. For large power transformers, painting booths are used.
Coil Winding, Assembly, Drying, and Oil Filling Workshop
Winding Section
Winding machines for round and rectangular wire for high-voltage coils and foil winding machines for low-voltage coils. For large power transformers, vertical or horizontal winding machines are also used.
Paper and Cardboard Section
This section is responsible for manufacturing all parts from paper and cardboard (paper cutting tables, longitudinal paper slitter, guillotine shears + punching press for busbars).
Assembly Section
This section is the assembly line for the active part; in addition to the conveyor line, a hydrodynamic press for coil clamping and drying ovens for the active part must be provided. After drying, transformers move to the next section.
Vacuum Filling Section
Transformer oil preparation (degassing) line and vacuum filling of transformers in an autoclave.
Testing Section
A comprehensive testing laboratory with a shielded chamber and an impulse generator. The testing station is the heart and face of the entire production, because a product is considered manufactured and ready for customers only after quality verification and confirmation by a test report. Our laboratory issues the report automatically, recording all indicators in the software during the testing process. It is on the test field where the customer is most often present to personally verify the quality of the purchased transformer (so-called witness tests).
The testing station is designed for the following routine tests during production and after repair:
Production Tests:
- Measurement of transformer insulation resistance.
- Measurement of the polarization index of insulation resistance.
- Measurement of voltage ratio of windings.
- Determination of the transformer vector group.
- Measurement of winding resistance with direct current.
Dielectric Strength Tests:
- Applied voltage test (high voltage).
- Induced voltage test (increased frequency).
Electrical Tests:
- No-load test (open circuit) with measurement of no-load losses and current.
- Load test (short circuit) with measurement of losses and short-circuit voltage.
- Transformer efficiency, %.
- Transformer voltage drop, %.
- Measurement of no-load current and voltage harmonics.
- Partial discharge measurement.
Type Tests:
- Temperature rise test.
- Lightning impulse test.
- Chopped lightning impulse test.