In 2019, Nanjing Daqo Transformer Co., Ltd. took a major step toward smart manufacturing by introducing a world-class intelligent, digital, and fully automatic iron core production line. This advanced shearing and stacking system was supplied by the renowned German equipment manufacturer GEORG, marking a milestone in the transformer industry’s transition from traditional manufacturing to fully digital production.
This production line enables end-to-end digital processing of silicon steel sheets—from raw material feeding to finished transformer core assembly—representing a breakthrough in efficiency, precision, and product consistency.
From Traditional Manufacturing to Intelligent Production
Traditional transformer core manufacturing relies heavily on manual lamination and semi-automatic equipment. While widely used for decades, this approach has inherent limitations, including labor dependency, inconsistent stacking accuracy, and variations in product quality. Noise control and no-load loss performance are also difficult to optimize under manual processes.
By contrast, the intelligent production line introduced by Nanjing Daqo Transformer integrates automation, digital control, and intelligent algorithms into every stage of the process. The system automatically completes steel sheet unwinding, precision shearing, burr control, stacking, and core forming, all under centralized digital management. This transformation significantly reduces human intervention and eliminates variability caused by manual operation.
Core Technologies of the GEORG Shearing and Stacking Line
The GEORG intelligent shearing and stacking line is recognized globally for its advanced engineering and reliability. Key technologies include high-precision servo control, intelligent sensor systems, and real-time data acquisition. Each silicon steel sheet is processed with micron-level accuracy, ensuring uniform dimensions and optimal magnetic performance.
The system supports digital parameter setting for different transformer models, enabling rapid switching between product specifications. Through intelligent optimization algorithms, cutting angles, stacking sequences, and lamination structures are automatically adjusted to achieve the best electromagnetic performance for each core design.
Significant Improvements in Production Capacity and Consistency
One of the most notable advantages of this intelligent production line is the dramatic increase in production capacity. Automated continuous operation allows for high-speed, stable output, far exceeding the efficiency of traditional manual lamination lines. At the same time, labor intensity is greatly reduced, improving workplace safety and operational stability.
More importantly, the line delivers exceptional quality consistency. Each transformer core is produced under identical digital conditions, ensuring uniform stacking tightness, alignment accuracy, and magnetic path continuity. This level of consistency is extremely difficult to achieve with manual processes.
Superior Transformer Performance: Lower Noise and Energy Loss
Thanks to precise shearing and optimized stacking technology, transformers produced on this intelligent line demonstrate outstanding performance improvements. Compared with traditional manually laminated transformer cores:
Operating noise is reduced by approximately 5 dB, significantly improving environmental friendliness and suitability for urban and indoor applications.
No-load loss is reduced by about 5%, contributing to higher energy efficiency and lower long-term operating costs.
These improvements are particularly valuable in today’s energy-conscious market, where efficiency standards and environmental regulations are becoming increasingly stringent.
A Benchmark for Smart Manufacturing in the Transformer Industry
The successful implementation of this intelligent, fully automatic iron core production line positions Nanjing Daqo Transformer at the forefront of smart manufacturing in the global transformer industry. It not only enhances the company’s competitiveness but also sets a new benchmark for digital transformation in transformer core production.
By combining German precision engineering with advanced digital manufacturing concepts, this production line demonstrates how intelligent equipment can fundamentally reshape traditional industries—delivering higher efficiency, better quality, and more sustainable performance for the future.
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