A digital dry-type transformer consists of a conventional main body and intelligent components. Its core is made of high-permeability silicon steel, with high and low-voltage windings manufactured by vacuum epoxy casting, Class H/C insulation, and air cooling.

The intelligent digital production line for dry-type transformers can adopt a linear flexible layout, covering core processing, winding manufacturing, and intelligent assembly, and can be equipped with fully automatic testing and warehousing, enabling full-process data collection and traceability. It boasts advantages such as one code per product, stable quality, flexible mixed production, and remote operation and maintenance, which can significantly boost production capacity.

Transformer Production Lines are suitable to Assemble/Produce Transformers. (If clients have more requirements or want to produce the other Transformers, welcome to contact us.)

Digital Dry-Type Transformer: Structure Introduction, Images & Suitable Production Line

1. Core Structure (Digital + Main Body)

1.1 Main Body Structure (Conventional Dry-Type Core)

• Core
  • Material: High-quality cold-rolled grain-oriented silicon steel (or amorphous alloy).
  • Technology: 45° full miter joint, multi-stage step lapping, low loss and low noise.
  • Structure: Three-phase three-column / five-column type, fastened with steel clamps and tie plates for high rigidity.
• HV & LV Windings (Epoxy Cast Type, Mainstream)
  • LV winding: Copper foil / rectangular copper wire, multi-layer cylindrical type, vacuum epoxy casting.
  • HV winding: Copper conductor, sectional layer type or continuous type, with the same casting process.
  • Insulation: Class H / Class C, vacuum pressure impregnation (VPI) / casting, moisture-proof, flame-retardant and self-extinguishing.
• Cooling System
  • Natural air cooling (AN) or forced air cooling (AF) with axial fans.
  • Air ducts: Reserved between windings and core for heat dissipation, fans accelerate air convection.
• Body & Base
  • Core and windings integrally compressed; high-strength steel base with damping pads.

1.2 Digital / Intelligent Components (Key Difference)

• Temperature monitoring: PT100/PT1000 sensors embedded in HV/LV windings and core for real-time temperature measurement.
• Intelligent temperature controller: Displays temperature, over-temperature alarm / trip, automatic fan start/stop, RS485/Modbus communication.
• Power monitoring: Voltage, current, power, power factor and energy metering.
• Condition sensing: On-line monitoring of partial discharge, vibration, humidity and SF6 (optional).
• Control & communication: PLC/MCU, Ethernet, WiFi, 4G/5G, MQTT/Modbus TCP/IP.
• Protection: Overcurrent, overheating, short circuit, door interlock, lightning protection.
• HMI: Local touch screen + remote cloud platform / APP.

2. Typical Appearance of Digital Dry-Type Transformer

3. Adapted Production Line: Intelligent Digital Production Line for Dry-Type Transformers

3.1 Overall Line Architecture

• Mode: U-shaped / linear flexible digital production line, integrating automation + informatization (MES/ERP/WMS).
• Logistics: AGV/RGV automatic transfer, three-dimensional warehouse, intelligent sorting.
• Control: 5G + industrial Internet, digital twin, full-process data collection and traceability.

3.2 Core Processes & Equipment

1. Core Processing LineAutomatic longitudinal shearing line, transverse shearing line, stacking table, step punching machine, intelligent painting and drying oven.Digitization: Automatic dimension inspection, burr closed-loop control, pre-loss detection.
2. Winding Digital Manufacturing UnitAutomatic HV winding machine, LV foil winding machine (constant tension, digital turn control); pre-baking, vacuum casting station, curing oven (MES online process monitoring); coil inspection: dimension, appearance, partial discharge, DC resistance.
3. Intelligent Assembly LineLifting assembly stations, core-winding assembling workstations, automatic fastener tightening; intelligent positioning, error-proofing and assembly parameter recording.
4. Digital Test Station (Critical)Fully automatic testing: ratio, vector group, DC resistance, no-load / load loss, power frequency withstand voltage, induced withstand voltage, partial discharge; automatic data collection, qualification judgment, report generation and cloud uploading.
5. Intelligent Logistics & WarehousingThree-dimensional warehouse for raw materials / semi-finished products / finished products, WMS, AGV/RGV distribution.
6. Master Control & Informatization SystemMES: planning, scheduling, process, quality, equipment, traceability.SCADA: real-time monitoring, alarm, visual large screen.Digital twin: virtual simulation, pre-commissioning, fault diagnosis.Cloud platform: remote O&M, customer viewing, big data analysis.

4. Highlights of the Production Line

• Full-process data traceability: One code (QR code / barcode) for the whole lifecycle from raw material to delivery.
• Quality stability: Automatic control of key parameters, less manual intervention, high consistency.
• Flexible production: Quick changeover, mixed production of multiple specifications for small-batch & multi-variety demands.
• Remote O&M: Remote viewing of line status, equipment OEE and order progress.
• Efficiency & delivery: Capacity increased by ~40%, shortened cycle, first-pass yield ≥99.5%.

5. Application Scenarios

• New energy: wind power, photovoltaic, energy storage, hydrogen energy step-up transformers.
• New infrastructure: data centers, 5G base stations, rail transit, charging stations.
• High-end buildings: high-rises, hospitals, schools, subways, underground spaces.
• Industry: chemical, metallurgy, mining, shipbuilding, high-end manufacturing.