How Oil-Immersed Transformers Are Manufactured: A Look at TSTYNICE's Production Process

Oil-immersed transformers are widely used across various industries due to their versatility and broad capacity range. At TSTYNICE, we follow a meticulous, technology-driven manufacturing process to ensure the highest quality standards. Here's an inside look at how we produce these essential power devices.

Core Production: The Foundation

The transformer core is the heart of the device, and we manufacture it using high-quality, grain-oriented silicon steel sheets for optimal magnetic performance. Our fully automated core production line achieves 95% automation, ensuring precision and consistency in every unit.

Raw Material Testing: Quality from the Start

Before assembly begins, all raw materials—including copper foil, insulating paper, porcelain bushings, and tap changers—undergo rigorous testing. This step is crucial to guarantee that only the best materials are used, enhancing the transformer's reliability and longevity.

Insulation Production: Safety First

Transformer insulation must withstand high voltages and extreme conditions. We cut insulation materials into precise shapes, then subject them to rounding, moisture-proofing, and quality checks. Any defects, such as cracks or foreign particles, are immediately addressed to prevent future failures.

Winding: Precision Engineering

Using advanced automated winding machines, we carefully layer copper or aluminum windings with exact tension control. This technology allows for fine adjustments in wire diameter, turns, and alignment, significantly improving efficiency and reducing human error.

Suiting Process: Ensuring Structural Integrity

To protect the core and windings, we use thick paper tubes that overlap sufficiently for added strength. The coils are fitted tightly to the core to prevent movement during operation, which is critical for maintaining transformer stability.

Welding: Strong and Reliable Connections

Automated welding equipment ensures that high- and low-voltage leads are securely joined. Real-time monitoring of temperature, pressure, and speed guarantees durable, defect-free welds.

Vacuum Drying: Eliminating Moisture

Moisture is a transformer's enemy. Our vacuum drying process removes all traces of humidity from insulation and windings, preventing electrical faults and extending the transformer's lifespan.

Vacuum Oil Filling: Enhancing Durability

Transformer oil must be free of bubbles and impurities. Our automated oil-filling system ensures complete degassing, and we only use high-grade oil that meets national standards.

Laboratory Testing: Final Quality Assurance

Every TSTYNICE transformer undergoes extensive testing in our CNAS-certified lab. Tests include lightning impulse, temperature rise, short-circuit impedance, and power frequency withstand voltage checks. These rigorous evaluations ensure that our transformers perform reliably in any environment.

Conclusion

From raw material selection to final testing, TSTYNICE’s transformer manufacturing process combines cutting-edge automation with strict quality control. Our commitment to precision and durability makes us a trusted name in the power industry.