The sealing performance of the oil tank is crucial for the long-term safe and stable operation of distribution transformers. In fact, sealing performance is one of the core indicators for measuring the quality and lifespan of distribution transformer tanks.
To improve the quality and shorten the lead times of corrugated transformer tanks, Zhihe purchased two additional collaborative robots - significantly improving seal quality and weld appearance.
Learn More About Corrugated Transformer Tanks
Specific risks and consequences that may result from transformer tank sealing failure:
1. Direct Consequences: Affecting Normal Equipment Operation
Pressure Protection Device Malfunction: If the seal fails and water enters, the vaporization of the water at high temperatures can cause an abnormal increase in internal pressure within the oil tank. This may lead to malfunctions of the gas relay or pressure relief valve, resulting in unnecessary power outages.
Abnormal Oil Level: Poor sealing can cause oil vapor to slowly leak from gaps. Prolonged leakage will cause the oil level to drop, potentially exposing the iron core or coils and leading to serious accidents.
2. Serious Hazards: Insulation Moisture Absorption and Oil Deterioration
Insulation Moisture Absorption: Transformer oil is hygroscopic. If the tank is not properly sealed, moisture from the air will enter, reducing the insulation strength between the transformer oil and the insulating paperboard. This can lead to partial discharge or, in severe cases, breakdown and short circuits, causing significant losses.
Oil Deterioration: At high temperatures, oxygen in the air reacts with the transformer oil to produce acids, sludge, and other substances. This darkens the oil's color, increases its viscosity, and raises its acid value, resulting in a permanent decline in the oil's cooling and insulation properties, ultimately requiring expensive replacement of the insulating oil.
Collaborative robots offer clear advantages over manual welding for transformer tank applications:
1. Lower Skill Barrier
Collaborative robots are easy to program. With a touchscreen interface and pre-installed welding routines, an operator can set up a job in minutes - no special training required. This reduces the need for highly skilled welders, freeing them from repetitive work so they can focus on more complex or custom jobs.
2. Better and More Consistent Weld Quality
Tank weld quality directly affects transformer sealing and service life. Collaborative robots equipped with laser positioning sensors can detect thermal distortion and fit up errors in real time, adjusting the torch path to keep the weld exactly where it should be. The result is consistent, clean welds with far fewer defects - such as porosity, localized distortion, or incomplete fusion.
3. Higher Efficiency and Shorter Lead Times
Unlike manual welding, collaborative robots run continuously and reliably across different weld types. Fully automated welding eliminates multiple manual tank flips, saving time and labor. One operator can tend several robots at once, cutting the welding cycle and significantly boosting overall throughput.
