Robotization in the Production of Distribution Power Transformers - Technologies, Advantages and Prospects of Industry 4.0

Abstract

This paper explores modern approaches to introducing robotic automation in the production of power distribution transformers within the Industry 4.0 framework. It identifies the key manufacturing stages where industrial robots provide the greatest efficiency, including electrical steel cutting, coil winding, magnetic core assembly, insulation application, tank welding, and quality control. Particular attention is given to integrating robotic systems with digital manufacturing management platforms, as well as using sensors, machine vision, and real-time monitoring technologies.

The findings show that robotic automation significantly improves precision and operational consistency, reduces production cycle time by approximately 30–40%, lowers defect rates from 5–7% to 2–3%, and decreases overall manufacturing costs by 15–20%. Additional benefits include improved energy efficiency, enhanced workplace safety, reduced occupational injuries, optimized resource use, and minimized human error.

The study concludes that implementing robotics in transformer manufacturing establishes a foundation for smart factories and fully automated intelligent production systems driven by digitalization, big data, artificial intelligence, and predictive maintenance.