This equipment is a heavy-duty intermittent circulating plate chain assembly production line, specially designed for batch assembly of large and ultra-heavy power transformers. It is one of the few dedicated production lines in this tonnage range that can cover full-process assembly of 3–15 ton complete machines.

Different from conventional transformer assembly lines, this line does not target light distribution transformers or small-capacity stations. Instead, it focuses on 10-ton class and above large transformers that are generally difficult to stably carry in the industry. It has a normal load capacity of 12 tons, can stably circulate complete machines with a total weight of up to 12 tons including accessories and oil, and can be upgraded to 18–20 tons. This load range accurately covers SZ11/S11-10000/35 type 35kV, 10000kVA main transformers (mass production project measurement benchmark: full configuration operating weight approx. 10.5 tons, core body net weight approx. 9.6 tons). It can directly undertake the full-process production of such large main transformers from core lamination stacking, coil assembly to vacuum oil filling and withstand voltage testing, without intermediate line transfer, reloading or repeated forklift transportation.

As a mature heavy-duty transformer assembly line, the product is suitable for assembly, commissioning and testing operations of all series of medium and high voltage power transformers, both oil-immersed and dry-type. It can meet the large-scale and customized production needs of heavy transformers with different capacities, voltage levels and weights, solving industry problems such as laborious manual handling of heavy transformers, easy collision of equipment, disordered processes, low commissioning accuracy and poor mass production efficiency. This transformer production line takes heavy load stability, process standardization and closed-loop circulation as its core, and is adaptable to mass production conditions of large equipment.

I. Scope of Applicable Assembly Products

The production line is specially designed for heavy power transformer assembly, adapts to mainstream transformer categories used in industrial step-down stations, photovoltaic power stations, industrial and mining enterprises, and urban distribution hubs. It supports flexible production of equipment with multiple specifications, large weights and large capacities, and the applicable parameters can be customized and expanded.

• Core applicable categories: Suitable for 10kV and 35kV class oil-immersed power transformers and dry-type power transformers, covering all series of energy-saving transformers such as S11, S13, SH15 amorphous alloy, SCB13, SCBH15.
• Capacity and weight adaptation: Conventionally adapts to 2000kVA–10000kVA large-capacity transformers, normally covering production of 3–15 ton heavy transformers; precisely adapts to SZ11/S11-10000/35 type 35kV, 10000kVA main transformers (mass production project measurement: full configuration operating weight approx. 10.5 tons, core body net weight approx. 9.6 tons). It can stably carry the circulation of complete machines with a total weight of up to 12 tons including accessories and oil, covering the full weight range from small and medium distribution transformers to large industrial main transformers.
• Compatible and expandable categories: Can adapt to special power equipment such as high-overload transformers, anti-corrosion transformers, main transformers for photovoltaic special box-type substations, and wind power supporting transformers, and supports assembly operations of non-standard customized structure transformers.
• Electrical parameter adaptation (customizable): Adapts to mainstream voltage transformation levels of rated voltage 10kV/0.4kV, 35kV/10kV, 35kV/0.4kV, meeting assembly standards for power frequency withstand voltage, induced withstand voltage, partial discharge, no-load loss, load loss and other tests.

All the above transformer products are compatible with the full processes of core lamination stacking, coil assembly, insulation assembly, oil tank welding, vacuum oil filling, complete machine commissioning and withstand voltage testing. The production line can adapt to differentiated assembly processes of equipment with different structures such as dry-type oil-free and oil-immersed sealed types, and is compatible with full-scene operations including semi-finished product pre-assembly, complete machine refined assembly, and factory complete set commissioning.

II. Overall Equipment Structure of the Production Line

The whole line adopts a heavy-duty closed-loop circulating plate chain conveying structure, with fixed station operation and dynamic circulation of heavy workpieces as the core. It integrates heavy-duty mechanical conveying, electrical control, safety protection and heavy lifting, realizing intermittent start-stop, station locking and positioning, and process linkage. The overall structure is modular, and the line length, number of stations and load tonnage can be customized as required to adapt to mass production conditions of 15-ton class heavy equipment.

Such large power transformer manufacturing line usually consists of four parts: conveying system, control system, protection system and lifting system. Each unit can be configured independently, and the heavy-duty station structure can be adjusted according to product processes.

1. Main Line Conveying Mechanical System

The conveying main body adopts thickened steel structure and high-strength alloy combined guide rails, driven by heavy-duty double chains synchronously. The frame is integrally reinforced and welded, with deformation resistance, impact resistance, wear resistance and pressure resistance. It is suitable for continuous operation of 10-ton class and above heavy transformers, avoiding line body deformation, operation jitter and chain slippage under heavy load conditions. The line body adopts intermittent conveying: heavy workpieces automatically stop and are mechanically locked and positioned after arriving at the station, and circulation is triggered after the station process is completed, with no idling. It is adaptable to refined, slow-paced and high-precision assembly of heavy equipment.

The line body has a built-in double-layer track closed-loop structure: the upper layer is the heavy workpiece operation conveying track, and the bottom layer is the tooling plate return track; large-tonnage lifting and traversing mechanisms are configured at the head and tail to realize automatic closed-loop circulation of heavy-duty tooling pallets, without manual handling or forklift transportation for return.

It is equipped with heavy-duty tooling pallets, which are integrally welded with thickened steel plates, with an integrated load-bearing structure, and configured with high-strength anti-collision structures and station coding identifiers; the bottom of the pallet is equipped with high-precision positioning mechanisms and heavy-duty blocking trigger sensing components, ensuring no offset when heavy-duty stations stop; the table top is reserved with adjustable anti-slip limit fixing structures, which can adjust the positioning spacing according to the transformer base size and weight distribution, avoiding displacement, collision and tipping during hoisting, assembly and commissioning.

The drive units of the whole line adopt high-power heavy-duty motor reducer configuration to strengthen the transmission structure. The static rated load per station is ≤20 tons, and the dynamic operation load is ≤12 tons, meeting the conveying demand of complete machines and semi-finished products of large-capacity heavy transformers. The start-stop buffer is controllable and the operation is stable, protecting the iron core, coil, oil tank and insulation structure from mechanical damage.

2. Electrical Control System

The whole line adopts PLC distributed control system with industrial bus signal transmission, realizing equipment linkage, signal acquisition, fault self-inspection, process interlocking and production beat regulation. It supports parameter debugging and program upgrade, can adapt to different process standards and production capacity rhythms, and can be connected to the workshop MES system to realize production data traceability, capacity statistics and equipment operation and maintenance monitoring.

The equipment is configured with vertical operation consoles, integrating touch screens, start-stop buttons, station call buttons and emergency stop buttons. It has functions such as whole line start-stop control, station status monitoring, visual statistics of operation data, sound and light fault alarm, manual fixed-point positioning, and single-station independent control, supporting both manual and automatic control modes.

Each assembly station is reserved with high-power industrial power supply interfaces and high-voltage pneumatic quick-plug interfaces, which can directly support electric fastening equipment, pneumatic assembly tools, vacuum oil filling equipment and testing instruments, without external long cables or long air pipes. The number, layout and power of interfaces can be adjusted according to station process requirements.

3. Safety Protection System

The whole line is equipped with high-strength metal mesh safety isolation fences to isolate the heavy equipment movement area from the personnel operation area, preventing extrusion and collision accidents caused by personnel accidental entry. The fences are reserved with maintenance safety doors equipped with interlock switches, and opening the door triggers the whole line to stop.

The system is provided with an emergency stop interlock circuit, integrating the main emergency stop of the operation console, independent emergency stop of each station, safety signals of fence maintenance doors, and line body overload protection signals. Any condition triggered will cause the whole line to stop and lock instantaneously. The whole line has overload protection, short circuit protection, limit protection, anti-seize protection and overweight warning functions.

4. Auxiliary Lifting Equipment System

The production line is equipped with a heavy-duty lifting operation system, adapting to the whole-process hoisting operations of 10-ton class and above transformer loading and unloading and heavy component assembly:

• Heavy-duty column-mounted cantilever crane (equipped with large-tonnage electric hoist): installed at the side of the station, used for precise fixed-point hoisting in a single station, meeting the assembly needs of heavy components such as transformer core body, iron core, coil and oil tank.
• Large-tonnage bridge crane (installed on the top of the workshop): responsible for heavy transformer blank loading, finished product unloading, and cross-station large component transfer, adapting to the mass production rhythm of large-capacity heavy transformers.

The tonnage, working radius and lifting stroke of the lifting equipment can be matched as required.

III. Assembly Process Flow (Stations can be added or reduced as required)

The whole line process conforms to the assembly process of the power transformer industry, adopting the mode of heavy workpiece circulation and fixed station specialized operation. Special stations can be added or reduced according to different processes of dry-type and oil-immersed products. The standard general flow is as follows:

1. Loading station: Hoist the transformer iron core, oil tank or complete machine blank to the heavy-duty tooling pallet through heavy lifting equipment, complete positioning, locking and fixing, and input production station information.
2. Core lamination stacking pre-processing station: Complete iron core correction, lamination assembly, insulation paving, iron core fastening, correct iron core flatness and clearance, and ensure magnetic circuit accuracy.
3. Coil assembly station: Complete high and low voltage coil sleeving, insulation wrapping, lead wire arrangement, coil fixing, regularize winding structure, and ensure electrical insulation performance.
4. Core body general assembly station: Complete overall assembly of iron core and coil, bracket fixing, insulation parts assembly, lead wire connection, fastener locking, and complete the main structure assembly of the transformer core body.
5. Oil tank assembly/sealing station (special for oil-immersed type): Complete oil tank splicing, welding and grinding, sealing rubber strip installation, cover plate fixing, check the tightness of the tank body, and prepare for the subsequent oil filling process.
6. Vacuum treatment and oil filling station (special for oil-immersed type): Carry out core body vacuum drying, vacuum oil filling, static pressure stabilization, discharge internal air and moisture, and improve insulation stability and withstand voltage performance.
7. Accessory assembly station: Install a full set of external accessories such as bushings, tap changers, temperature controllers, fans, pressure relief valves and oil level gauges to complete the structural improvement of the complete machine.
8. Electrical performance commissioning station: Carry out transformation ratio test, DC resistance test, insulation resistance test, no-load loss and load loss test, and calibrate equipment electrical parameters.
9. Withstand voltage and complete machine testing station: Conduct power frequency withstand voltage, induced withstand voltage, partial discharge, sealing leak detection, temperature rise simulation test, comprehensively check equipment hidden dangers, and ensure equipment compliance.
10. Finished product unloading station: Hoist and unload the qualified transformer finished products into the warehouse, and the empty tooling pallets automatically return to the loading station through the lifting and traversing mechanism to enter the next cycle.

The whole transformer assembly line connects each process continuously through fixed beats and automatic circulation, reducing work-in-process accumulation and transportation loss.

IV. Core Advantages and Customization Capabilities

1. Improvements over Traditional Assembly Modes

Traditional heavy transformer assembly adopts equipment floor placement, frequent forklift transportation, and manual close-range handling and adjustment, which has problems such as difficult transportation of heavy equipment, collision and deformation, easy damage of insulation layer, disordered processes, low parameter commissioning accuracy, high labor intensity and low mass production efficiency. This assembly line adopts assembly line operation: workers are fixed at professional stations, heavy workpieces circulate automatically and smoothly, the process division is clear and the operation standards are unified. It reduces handling frequency, reduces collision damage to iron core, coil, oil tank and sealing structure, and ensures insulation performance and electrical parameter stability; the closed-loop circulation structure eliminates the need for manual transfer of tooling, reduces heavy work rate and labor cost, improves production beat and workshop site utilization, and adapts to large-scale and standardized mass production of large-capacity heavy transformers.

2. Customizable Parameters and Configurations

• Line body parameters: The total length, width and height of the line body can be customized according to the workshop site, 8–18 standard stations can be set, and single-line, double-line and circular layouts can be adapted.
• Heavy load capacity: Standard normal load capacity is 12 tons, which can be upgraded to 18–20 tons for special ultra-heavy transformers. Tooling pallets with different sizes and load-bearing structures can be customized to adapt to various non-standard transformer base specifications.
• Process configuration: Modules such as automatic welding, vacuum drying, testing, data traceability and appearance re-inspection can be added as required. The station sequence can be adjusted and special stations can be added or reduced according to the process standards of dry-type, oil-immersed and special transformers.
• Control functions: Support production data statistics, real-time capacity monitoring, fault traceability, automatic report generation, can be connected to MES and ERP systems, and can customize manual/automatic/semi-automatic operation modes.
• Protection configuration: Dust-proof, moisture-proof, rust-proof and noise reduction can be configured as required, adapting to the standards of dust-free assembly workshops for power equipment. Fence styles, emergency stop layouts and interlock logic can be customized.

V. Summary of Core Equipment List

VI. Heavy-Duty Positioning (Industry Differentiation Perspective)

1. Why Focus on “Large / Ultra-Heavy”

In the field of transformer assembly equipment, most production lines are designed for light distribution transformers and small and medium capacities, with load capacity generally staying in the 3–5 ton range. When it comes to 10-ton class large transformers, they are often forced to rely on forklift transportation due to insufficient line body rigidity, insufficient drive margin and unstable circulation, making it difficult to form a continuous assembly line.

This extra-heavy-load transformer line is designed for heavy load from the beginning of structural design: the frame is integrally reinforced, double chains are driven synchronously, and the drive unit strengthens the transmission. The static rated load per station is ≤20 tons, and the dynamic operation load is ≤12 tons, with a normal load capacity of 12 tons and upgradeable to 18–20 tons. This enables complete machines of 15-ton transformer production line level to complete the whole process from pre-assembly to factory testing on the line, without intermediate line transfer or reloading.

2. Load Range and Measured Benchmark

Taking SZ11/S11-10000/35 type 35kV, 10000kVA main transformer as the measured benchmark (mass production project measurement: full configuration operating weight approx. 10.5 tons, core body net weight approx. 9.6 tons), its full configuration weight stably falls within the normal 12-ton load range, verifying the actual adaptability of this line to large main transformers.

3. Production Value Brought by Heavy-Duty Design

• Reduced transportation: Heavy workpieces circulate automatically and smoothly, avoiding collision and insulation layer damage caused by frequent forklift intervention;
• Guaranteed accuracy: Station locking and positioning, controllable start-stop buffer, protecting iron core, coil, oil tank and sealing structure;
• Improved beat: Closed-loop circulation eliminates manual transfer of tooling, improving site utilization and mass production efficiency;
• Full scene coverage: Compatible with oil-immersed, dry-type and special transformers, adapting to large-scale, standardized and customized production.