Major Transformer Manufacturer Core Slitting Line Upgrade
A transformer manufacturer with 5,000 units annual capacity achieved 50% precision improvement and 60% labor reduction by adopting a fully automated silicon steel slitting line.
Project Background
The client is a leading distribution transformer manufacturer in South China with an annual output of approximately 5,000 units. As order volumes grew and customer quality requirements increased, their existing semi-automatic slitting equipment could no longer meet production demands.
Key Challenges
- Unstable slitting precision, with width tolerances fluctuating around ±0.15mm
- Time-consuming manual changeovers, requiring 3 operators per line
- Frequent burr issues requiring an additional deburring process
- Low production efficiency impacting delivery schedules
Solution
CRAYTRON provided the client with a Slitter-500 heavy-duty slitting line, configured with:
- Dual servo-driven slitting heads: Enabling parallel processing for maximum throughput
- Closed-loop tension control: Ensuring material stability throughout the shearing process
- Quick-change blade cassette: Reducing changeover time from 4 hours to 30 minutes
- Integrated coil car: Automating material handling
Results
| Metric | Before | After | Improvement |
|---|---|---|---|
| Slitting Accuracy | ±0.15mm | ±0.05mm | 67% improvement |
| Burr Height | 0.03mm | ≤0.01mm | 67% reduction |
| Operators | 3/line | 1/line | 67% reduction |
| Daily Output | 8 tons | 15 tons | 87% increase |
| Changeover Time | 4 hours | 30 minutes | 87% reduction |
Client Feedback
“CRAYTRON’s slitting line has completely transformed our core production process. With improved precision, the rework rate in the lamination process has dropped significantly, and the no-load loss of finished transformers has decreased by 3%.”
Conclusion
This case demonstrates the value of fully automated slitting equipment in transformer core manufacturing — not just in capacity improvement, but more importantly in quality consistency and production flexibility.