Product Requirements

1. Customer background:

◦ Customer Type: A German automotive parts manufacturer specializing in core engine components, with an annual production capacity of 1.5 million units.

◦ Industry: Industrial Manufacturing

◦ Key requirements: The workshop will add three engine cylinder production lines, requiring a 1600kVA oil-immersed transformer with 10kV input and 0.4kV output. Located in the factory's central area, the system must operate at ≤65dB noise level (to avoid disturbing nearby offices) and ≤1.5kW no-load loss (compliant with EU energy efficiency standards). It must obtain CE certification (EN 60076) and complete production, cross-border delivery, and on-site installation guidance within 45 days.

2. Pain Points and Challenges:

◦ Technical challenges: The existing 800kVA transformer can only support the load of two production lines, and adding new lines would cause voltage instability. The workshop has only 3m×4m of available installation space, while the conventional 1600kVA transformer (standard dimensions: 4.2m×2.8m) is too large to fit.

◦ Compliance requirements: The product must obtain CE certification and provide a TUV Rheinland-issued noise and wear test report to ensure compliance with Germany's' Industrial Equipment Noise Emission Standard'.

◦ Time requirement: The customer's production line is scheduled to start operations in 3 months, and the transformer must arrive within 45 days. Otherwise, the production schedule will be delayed, resulting in an average daily loss of approximately 50,000 euros.

Solution

1. Solution Positioning:

◦ Product package: 1 customized 1600kVA oil-immersed transformer (model: S13-M-1600/10) + 1 intelligent temperature control system (real-time oil temperature monitoring with automatic cooling fan start/stop)

◦ Core Value: Featuring a "flat-core design with compact windings", the unit achieves a compact size of 2.8m×2.5m×2.2m (35% space-saving), perfectly fitting 3m×4m installation areas. Noise levels are controlled at 62dB (3dB below customer requirements), with no-load loss of 1.3kW (0.2kW below requirements). The entire system is CE-certified and can be directly connected to the German power grid.

2. Technical Highlights:

◦ Transformer: Made of 30Q130 high-permeability silicon steel sheets (reducing hysteresis loss) with 120mm² oxygen-free copper windings (minimizing copper loss). The oil tank features a corrugated design (replacing traditional radiators to reduce size while enhancing heat dissipation). Shock-absorbing pads are installed at the base to minimize operational vibration and noise.

◦ Intelligent Temperature Control System: Equipped with PT100 temperature sensors (±0.5℃ accuracy), supports RS485 communication, and can connect to the customer's workshop PLC system for real-time remote monitoring of oil temperature and load current.

◦ Installation adaptation: The transformer features a detachable lifting ring at the top and adjustable feet at the bottom to accommodate slight unevenness of the workshop floor.

3. Compliance Guarantee:

◦ Certification List: CE (EN 60076-1/2/3), TUV Rheinland Noise Test Report (62dB), TUV Rheinland Loss Test Report (No-load Loss 1.3kW), ISO 9001 Quality Management System Certification

◦ Compliance Statement: The anti-corrosion treatment for the transformer tank employs a "phosphating + epoxy resin spraying" process, compliant with the German DIN 50021 standard (adapted to the humid climate of Germany). All electrical components are sourced from EU-compliant brands (e.g., Siemens insulation paper, ABB terminals).

Product Design

1. design basis ：

◦ Reference standards: GB/T 1094.1-2013 "Power Transformers-Part 1: General Principles", EN 60076-1 "Power Transformers-Part 1: General Principles", DIN 50021 "Classification of Atmospheric Corrosion"

◦ Customization highlights: For a 3m×4m installation space, the iron core diameter is reduced from the standard 1.2m to 1.05m (using high-permeability silicon steel sheets to compensate for magnetic flux density); the winding height is lowered to 1.8m with a "double-layer winding" technique (reducing axial dimensions); the oil tank length is shortened from 4.2m to 2.8m, replacing the traditional radiator with a corrugated structure (maintaining the same heat dissipation area).

3. Key technical parameters table:

Delivery & Implementation

2. Fulfillment process:

◦ Production cycle: Total cycle 32 days (10 days ahead of the customer's requirement). Key milestones:

▪ Days 1-3: Design plan confirmation + Raw material procurement (silicon steel sheets, copper wires, insulating paper, etc.)

▪ Days 4-18: Core stacking (5 days) + Winding (8 days) + Body drying (3 days)

▪ Days 19-28: Tank welding + final assembly + factory inspection (pressure test, noise test, wear test)

▪ Days 29-32: Vacuum packaging + Wooden pallet reinforcement + Logistics containerization

◦ Cross-border logistics: Choose COSCO Shipping's dedicated' Chongqing Port → Rotterdam Port' route with a 22-day voyage (6 days faster than standard sea freight), featuring full-service handling throughout the journey.

▪ Customs clearance: We provide CE certification, commercial invoices, and packing lists, with customs clearance completed in 1 day at Chongqing Port.

▪ Customs clearance: Coordinate with local German customs brokers in advance, submit TUV inspection reports, and complete customs clearance within 3 days after arrival.

▪ Inland delivery: After customs clearance, the goods are delivered to the customer's factory by DB Schenker, a German logistics provider, using flatbed trucks, with a delivery time of 2 days.

▪ Day 4: No-load trial run + Load test (test voltage stability by connecting one production line)

▪ Day 5: Client team training (covering daily maintenance, troubleshooting, and temperature control system operation) + acceptance signing

3. quality control ：

◦ Production Testing: Implementation of the "Three-Inspection System"

▪ Raw material inspection: Silicon steel sheets are tested for magnetic permeability (≥1.8T), copper wires for resistivity (≤0.0172Ω·mm²/m), and insulating paper for temperature resistance (≥155℃). All tests are accompanied by supplier-provided inspection reports.

▪ Process inspection: Check the flatness of core stacking (error ≤0.5mm) and winding tightness (tension controlled at 50±2N) every 2 hours.

▪ Factory-wide inspection: in accordance with EN 60076, the following shall be completed:

• Lightning impulse test (750kV impulse voltage applied from 10kV side, no breakdown)

• Short-circuit withstand capability test (31.5kA short-circuit current, duration 2 seconds, with no winding deformation)

• Noise test (62dB at 1m during no-load operation, meeting requirements)

◦ examining report ：

▪ Ouxue Electric Factory Inspection Report (including 20 items of test data)

4. Project Timeline:

◦ Total cycle: 32 days for production + 22 days for shipping + 5 days for customs clearance and delivery + 5 days for on-site service = 64 days (1 day ahead of the customer's 45-day delivery and installation requirements, with a 10-day buffer period)

◦ Key node visualization:

Contract signing (Day0) → Production completion (Day32) → Ship loading at Chongqing Port (Day33) → Arrival at Rotterdam Port (Day55) → Delivery to customer factory (Day60) → Installation and acceptance completed (Day65)