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

Авторы:

Smailova G.A. (Первый автор)

A.Uderbaeva (Соавтор)

Y. Zhamankulov (Соавтор)

Издательство:

Вестник ЕНУ имени Л.Н. Гумилева

Дата издания

03.02.2026

На каком языке издана

Английский язык

ISSN

2616-7263

Область исследования

Инжиниринг и технологии

Тип исследования

Прикладное

Аннотация (краткое описание)

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.

Соответствие целям устойчивого развития (ЦУР)

URI

https://official.satbayev.university/ru/research/vestnik-satbayev-university

DOI

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.

Тип публикаций

Статья

Практическое значение

The practical significance of this study lies in demonstrating the effectiveness of robotic automation technologies for improving the efficiency, quality, and reliability of power distribution transformer manufacturing within the Industry 4.0 paradigm. The proposed approaches enable the automation of critical production stages, including steel cutting, coil winding, core assembly, welding, insulation application, and quality inspection, resulting in higher precision and operational consistency. The research findings show that the integration of industrial robots with digital manufacturing platforms, sensor systems, machine vision, and real-time monitoring technologies can substantially reduce production cycle times, minimize manufacturing defects, and lower overall production costs. These improvements contribute to enhanced product quality, increased competitiveness of manufacturing enterprises, and more efficient use of materials and energy resources. An important practical contribution of the study is the demonstration of how robotic systems improve workplace safety by reducing hazardous manual operations and decreasing the risk of occupational injuries. In addition, the implementation of predictive maintenance and intelligent monitoring systems allows manufacturers to reduce equipment downtime and optimize maintenance schedules.

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Файлы документа

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