Production line for assembling transformer stations
KTB Machinery developed a complete production line for the efficient and safe assembly of transformer stations. The installation is designed around the platform on which the transformer stations are placed and processed, and is suitable for both 10-tonne and 12-tonne platform trolleys. A reliable, powerful and safe line that fits perfectly with our client’s production processes.
This solution builds on our experience with moving floors: floor sections that can automatically move products in multiple directions. This technology was further developed into a powerful, modular transport concept for large prefabricated components and 3D units.
Structure of the production line
The complete package consists of four identical installations, each comprising:
- 8 platforms
- Conveyor system
- Hydraulic system with cylinders
- Milled rail at the front
- Rails on the floor at the rear
- Control system with 2× hold-to-run operation
- Platform insertion and centring mechanism including first rear platform
- End stop
Together, these components form a production environment in which heavy transformer stations can be handled in a controlled and safe manner.
Platforms: sturdy, stable and safe
The platforms form the basis of the production line. They are designed for:
- the even distribution of heavy transformer stations
- transfer forces during movement
- safe operation without any risks
- effortless transport between processing stations
Each platform has robust steel wheels, creating a strong yet smoothly moving base.
Hydraulics and guidance
The platforms are transported by powerful hydraulic cylinders, which move the platforms simultaneously to the next position. The guidance system ensures that the platforms can only move in one direction and remain stable at all times.
In addition, guide posts ensure simple and precise positioning when deploying a new platform.
Cycle time & speed
The standard cycle time is 120 seconds, but by using:
- frequency-controlled acceleration and deceleration
- pressure relief valves for pressure safety
- additional hydraulic power
The cycle time can be approximately halved without compromising safety or control.
New system parameters:
- Forward stroke: 60 seconds
- Return stroke: 60 seconds
Guide posts ensure simple and precise positioning when deploying a new platform.
Commissioning, FAT, SAT and UAT
Commissioning in Hattemerbroek
All installation components are fully assembled and functionally tested in Hattemerbroek. This is where the first full line inspection takes place.
FAT – Factory Acceptance Test
Following commissioning, a FAT is carried out in conjunction with the customer. We will follow a jointly drawn-up test protocol. Upon approval, the installation is released for transport.
SAT – Site Acceptance Test on site
The production line is reassembled at the customer’s site. This is followed by the SAT, during which we will fully integrate and test the line in the actual production environment.
UAT – User Acceptance Test
During the UAT, operators and other end-users assess whether the line is logical, user-friendly and works in practice. Any outstanding issues are resolved or adjusted as soon as possible.
View more projects
Projects involving robotics, smart engineering and automated production lines to improve production efficiency.
Why a carousel system?
Efficient transport
Automatic and controlled movement of elements, reduced waiting time, higher output.
Flexible production
Suitable for various prefab sizes, configurations and production routes.
Optimal use of space
Transport is integrated into the floor → no forklifts, less internal traffic.
Safety & reduced damage
Smooth movement prevents damage and reduces safety risks.
Cost-effective
Higher production capacity, less downtime and lower handling costs.
Want to make your production process more efficient too?