Increased Transformer Demand Requires Change
Industry: Power Generation
Application: Dry-type Transformers
Product: Automated Impregnation System
The Challenge
A prominent North American Transformer Manufacturer faced a significant "good problem to have" problem - four consecutive years of aggressive growth. However, their existing production methods for dry-type transformers couldn't keep pace with this increasing demand. The primary obstacles included:
- A critical need for higher throughput to sustain their growth trajectory.
- Reliability issues in the manual impregnation process.
- The requirement for a more accurate, repeatable solution for resin application.
- A desire to modernize production while maintaining strict quality standards.
The Solution
HeatTek engineered a fully integrated, automated system featuring a Transformer Dip System paired with two custom curing ovens. The solution utilized a polyester resin impregnation process, specifically designed with the following expert features:
- Automated resin filling and draining
- Operator platform
- Vacuum storage of resin
- Pneumatically operated lid
The Results
The implementation successfully transformed the client's manufacturing floor into a high-efficiency hub. By moving to an automated impregnation process, the manufacturer achieved their goal of increased production capacity without the need for additional labor. Key outcomes include:
- Significant increase in total throughput to meet multi-year growth demands.
- Reduction in the number of operators required to run the equipment.
- Improved process consistency and reduced human error in resin application.
- Enhanced workplace safety through automated material handling and environmental controls.
Support
The partnership between the manufacturer and HeatTek has extended well beyond the initial installation. They continue to ensure the system operates at peak performance through a commitment for the lifetime of the equipment:
- Spare Parts - Reliable delivery of essential components to prevent unplanned downtime.
- System Upgrades - HeatTek has since designed and implemented a major upgrade for the first two systems to keep pace with evolving technology.
- Technical Expertise - Ongoing collaboration to refine the automated process as the customer's product line expands.