Double Breakthroughs in Digital Transformation & Core Iron Core Technology! Ansheng Completes Full Production Line and New Energy-saving Transformer Technical Upgrade

In response to the Implementation Plan for High-quality Development of Energy-saving Equipment issued by MIIT and the updated national energy efficiency standard GB 20052, Hebei Ansheng Electric Power Equipment has recently completed two major technological upgrades. The enterprise fully iterated its MES digital production system and achieved new breakthroughs in manufacturing processes for three-dimensional wound cores and amorphous alloy cores. Meanwhile, new-generation ultra-low-loss transformers (S22 & SCB18 series) equipped with intelligent online monitoring modules have been launched, delivering technical strengths to meet market demands of new power systems, new energy supporting facilities and energy-saving renovation for data centers.

1. Comprehensive Digital Intelligent Transformation Build Closed-loop Data Traceability

The digital renovation covers four core workshops including iron core processing, winding production, vacuum drying and finished product testing. A new generation MES manufacturing execution system has been deployed, connecting data interfaces of ERP warehouse management, PLM product design and laboratory testing. It realizes online control of the whole process, from order distribution and raw material cutting to process circulation and factory tests. New CNC cross-shearing machines, integrated foil winding equipment, intelligent vacuum drying kilns and multi-physics simulation platforms are installed, together with full-coverage IoT sensors in workshops. Equipment operation parameters, machining precision and quality inspection data are uploaded to the cloud in real time. After transformation, silicon steel utilization rate rises by 8%, winding defect rate drops by 62%, and the production cycle per transformer shortens by 15%. Each product is assigned a unique code for full-lifecycle traceability, fully complying with digital quality control verification requirements in State Grid and China Southern Power Grid bidding projects.

Supported by the upgraded national-level intelligent comprehensive testing center, automatic integrated testing stations for temperature rise, partial discharge and short-circuit loss are newly added. 100% of finished products pass complete type tests before delivery. Test reports are automatically generated and archived, lifting testing efficiency by 40%, and test data can be synchronized to grid material storage audit platforms.

2. Iteration of Core Iron Core Processes Further Reduces Energy Loss

The R&D team optimized manufacturing techniques for silicon steel 3D wound cores and amorphous alloy cores: First, the new process for silicon steel three-dimensional wound cores optimizes continuous winding and oblique joint forming, eliminating air gaps in magnetic circuits. Compared with traditional laminated cores, no-load loss is cut by another 22% and operating noise reduces by 16 decibels, with greatly enhanced short-circuit resistance, ideal for industrial parks and distribution networks. Second, breakthroughs are made in forming ultra-thin amorphous alloy strips to solve brittleness and precision control difficulties. Optimized curing and shock-absorbing suspension structures enable SH25 and SCH19 amorphous transformers to reduce no-load loss by up to 78% against ordinary silicon steel products, perfectly fitting long light-load operation of photovoltaic and energy storage power stations.

New S22 oil-immersed, SCB18 dry-type and SBH25 amorphous 3D transformers manufactured by upgraded processes all meet Class 1 energy efficiency standards under GB 20052. Some models exceed national loss limits by over 15%, saving more than 10,000 kWh electricity annually per 1000kVA unit, fully aligning with national Dual Carbon policies for stock equipment replacement.

3. Intelligent Transformer Monitoring Technology Realizes Integrated Remote Operation & Maintenance

Independent R&D of intelligent monitoring modules is finished in this round of technical upgrading. New Class 1 transformers can be embedded with multi-dimensional sensors tracking temperature, current, partial discharge and power loss. Real-time operating data is uploaded to cloud platforms to support remote early warning, load analysis and power-saving diagnosis, shifting maintenance mode from passive overhaul to active risk prediction and greatly cutting post-operation costs for new energy stations and data centers.

As a Hebei Provincial "Specialized, Refined, Unique & Innovative" and national high-tech enterprise, Ansheng keeps increasing R&D investment. This digital and product upgrade has obtained 5 new utility model patents, enriching the company’s independent intellectual property portfolio. A senior technical manager stated that the company will cooperate with industrial laboratories to develop large-capacity 35kV amorphous 3D transformers and further advance unmanned workshop reconstruction. Leveraging dual strengths in intelligent manufacturing and energy-saving core technologies, Ansheng will keep supplying high-standard green power distribution solutions for power grid and new energy projects at home and abroad.