| Equipment | Assembly Platform (Motorized Lifting Type) |
| Customer | A power transformer manufacturer in Sohar, Oman (serving Middle East and East African grid markets) |
| Application | Body assembly and high-voltage lead connection for large and medium-sized oil-immersed transformers |
Customer information has been anonymized; only regional and industry attributes are retained. Performance figures represent typical reference values under standard operating conditions and may vary depending on actual production line conditions.
Customer Background
This power transformer manufacturer, located in the Sohar Industrial Zone of Oman, supplies 50 MVA to 150 MVA oil-immersed transformers for utility grid upgrades across the Middle East and transmission projects in East Africa. As the share of 110 kV and higher-voltage products in its order book has grown steadily, single-unit body heights frequently exceed 2.5 meters. The traditional scaffolding-and-ladder approach the shop floor had relied on was no longer able to keep pace with both throughput and safety requirements.
Industry Pain Points
Body assembly is one of the most demanding steps in transformer manufacturing, requiring precise positioning, safe working heights, and coordinated teamwork. Before introducing a dedicated assembly platform, the customer used fixed scaffolding and movable ladders:
Non-adjustable working height. Once scaffolding was erected, its height could not be changed to match different transformer body sizes. Workers had to climb up and down repeatedly to move ladders, wasting time and increasing fall risk.
Poor lighting and inconvenient power supply. The interior and top of large transformer bodies were poorly lit. Operators dragged temporary lighting and extension cords for hand tools into tight spaces, creating trip hazards and entanglement risks around energized equipment.
Low assembly efficiency. Large-body operations — winding insertion, core clamp installation, and high-voltage lead connection — require multiple workers at different elevations simultaneously. With fixed scaffolding, crew positioning was restricted, collaboration was awkward, and assembly cycle times for a single unit often reached two to three days.
Limited mobility. Fixed scaffolding could not be moved along the length of the transformer body. After completing work on one side, the crew had to dismantle and rebuild the scaffold on the other side, consuming significant non-productive time.
Solution
After an on-site workflow assessment, the customer selected the TRANFOVIA motorized lifting assembly platform. The machine’s design directly addresses each of the pain points described above.
Motor-driven lifting system for precise height adjustment. The platform uses a motor-driven lifting mechanism combined with a worm-gear reducer and lead-screw drive, delivering smooth and accurate height adjustment. A hydraulic lifting option is also available on request. The platform can be quickly raised or lowered to match the body height of different transformers, eliminating the need for workers to climb ladders repeatedly and allowing operators to work at the optimal ergonomic position for winding insertion, lead connection, and insulation fitting.
Dual safety locking protection. Both electrical and mechanical self-locking systems are integrated into the design, ensuring that the platform remains securely at any programmed height during extended assembly operations. This dual protection significantly reduces the risk of unexpected descent.
Extendable working surface. The platform features extendable plates with positioning pins that can be deployed when additional workspace is needed. Workers can reach both sides or the top of the transformer body without overreaching, while perimeter guardrails prevent operators from leaning too far.
Built-in power and lighting. Integrated power sockets and adjustable crank-arm lamps with high-power lighting are built into the working platform. Operators can plug in electric wrenches, heat guns, and other tools directly at the workstation, eliminating temporary cords and improving both illumination and electrical safety.
Polyurethane heavy-duty casters for flexible mobility. The platform rides on polyurethane wheels that offer high load capacity, floor protection, and anti-static performance. Even under full load, the platform can be rolled smoothly along the shop floor, allowing it to be repositioned along the transformer body without disassembly. This mobility cuts the time required to move from one side of the body to the other from hours to minutes.
Dual-station intelligent control. Control stations are located both at ground level and on the platform itself, with interlock protection to prevent accidental operation. Workers can choose the most convenient control position based on their location, improving operational convenience and safety.
Implementation
- Sizing and customization consultation. TRANFOVIA’s technical team reviewed the customer’s maximum body height (approximately 3.2 m), maximum body weight (approximately 18 tons), and shop-floor track layout, then recommended a 15-ton motorized lifting assembly platform with customized platform extension lengths and guardrail heights.
- Factory acceptance testing. Before shipment, the platform underwent full-stroke lifting tests, locking-function verification, and load-running trials. The customer confirmed lifting smoothness and locking reliability through a remote video acceptance session.
- Sea freight and on-site commissioning. The equipment was shipped from Ningbo Port to Sohar Port, Oman, with a sea transit time of approximately 18 days. After arrival, a TRANFOVIA service engineer completed installation, floor-track alignment, and full-load lifting tests within one week. A three-day training program followed for operators and maintenance staff, covering lifting operation, safety-lock inspection, daily lubrication, and emergency procedures.
Results
After three months of operation, the customer recorded measurable improvements in the body assembly area (Results may vary):
- Assembly cycle time reduced from two to three days down to one to one-and-a-half days per unit, mainly due to the elimination of ladder repositioning and reduced climbing.
- Crew size optimized from six to seven operators per shift to four to five, because the extendable platform allows each worker to cover a larger work area and collaborate more efficiently.
- Temporary cords and handheld lighting reduced by approximately 80 percent, thanks to integrated power outlets and fixed lighting. The shop-floor safety audit score improved noticeably.
- Platform repositioning time cut from one to two hours to roughly 15 minutes, as the polyurethane casters allow the assembly platform to be rolled along the transformer body quickly, compressing non-productive time significantly.
Customer Feedback
“Before, once the scaffolding was set up it couldn’t be moved. Workers climbed up and down with tools, and by the end of the day output was low. With the motorized platform, we can raise or move the work surface as the assembly progresses, and operators can complete winding insertion and lead connection while standing on the platform. Our assembly cycle has been cut by more than half.” — Body assembly workshop supervisor, Sohar plant
Next Steps
If your transformer factory is struggling with fixed working heights, poor lighting and power access, or long assembly cycles during body assembly, contact us for detailed technical specifications and sizing guidance. TRANFOVIA can provide a customized proposal based on your transformer body dimensions, load requirements, and shop-floor layout.
- WhatsApp: +86-15958243831
- Email: sales@tranfovia.com
- Website: https://tranfovia.com/
