由 Yaming Overall Introduction
Our factory’s transformer assembly line integrates precision manufacturing and intelligent management. It covers the entire process from core component processing to finished product inspection and delivery, ensuring transformer quality through efficiency, precision, and flexibility.
1. Core Component Processing: Iron Core Production
For core component processing, we prioritize iron core production. An imported CNC silicon steel sheet shearing machine auto – adjusts cutting sizes for different transformer specifications, controlling shearing accuracy error within ≤0.05mm. The subsequent stacking uses an automated lamination machine with infrared positioning to stack silicon steel sheets neatly, achieving a lamination coefficient of over 97%—reducing core magnetic loss. Compared to traditional manual stacking, this lowers the loss rate by 5% and boosts production efficiency by 30%.
2. Highlighted Winding Process
The winding process is also a key focus. Multiple intelligent CNC winding machines support winding copper, aluminum wires, and other types. These machines feature a built – in automatic tension adjustment system that monitors wire tension in real time, ensuring tight and uniform coil winding to avoid loose strands or overlapping wires. After winding, an automatic coating machine precisely wraps insulating paper, with insulation layer thickness deviation ≤0.02mm and a 100% insulation performance compliance rate—laying the foundation for safe transformer operation.
3. Automated Final Assembly & Commissioning
During final assembly and commissioning,the production line operates with high automation. AGV unmanned carriers distribute cores, windings, fuel tanks, and other components to stations via preset routes, reducing manual handling errors. An automated total loading machine assembles cores and windings using a robotic arm, controlling fuel tank assembly coaxiality error within ≤0.1mm. After assembly, transformers undergo strict testing, passing 8 professional tests (including insulation resistance, transformation ratio, and load loss tests). Each product receives a unique test report to ensure compliance with national standards.
4. Intelligent Management System for Optimization
The production line is equipped with an intelligent management system that collects real – time operating data of each equipment via the Internet of Things (IoT). A big data analysis platform optimizes production rhythm and automatically warns of equipment abnormalities, reducing failure rates by 25%. It supports mixed – line production of 3–5 transformer specifications, with changeover time shortened to 40 minutes. Order delivery cycles are 15% shorter than industry averages, achieving dual improvements in quality and efficiency.
