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Basculeur hydraulique de 50 tonnes pour la fabrication de noyaux de transformateurs ultra-lourds

Présentation du client

In high-voltage power equipment manufacturing, handling ultra-heavy components like transformer cores requires both immense power and surgical precision. This case study highlights a 50-ton Hydraulic Tilter engineered for Tianjin TBEA in collaboration with the Beijing Machine Tool Research Institute (BMID). This heavy-duty solution addresses the critical need for safe, controlled 0-90 degree orientation of large-scale transformer assemblies.

Défi et solution

Défis pour les clients

Manufacturing large power transformers involves shifting massive core-and-coil assemblies from a horizontal assembly position to a vertical testing or tanking position. The primary engineering challenges include:

  • Structural Integrity: Preventing any deformation or stress on the transformer core during the transition.

  • Load Dynamics: Managing a 50,000kg load where the center of gravity shifts significantly during the 90-degree tilt.

  • Operational Safety: Eliminating the high risks associated with using overhead cranes for “flipping” heavy industrial components.

Solution personnalisée GRADIN

Our 50-ton hydraulic tilter (as shown in the project site image) features a reinforced blue structural frame and a specialized yellow tilting platform. The system is designed with advanced hydraulic logic to ensure a smooth, vibration-free transition.

Technical Logic & Synchronization

The system utilizes synchronized high-pressure hydraulic cylinders governed by a precision PLC. This ensures that the two sides of the platform move in perfect unison, preventing any torsional stress on the 50-ton load. The platform surface is equipped with heavy-duty support points and rollers to facilitate the positioning of the transformer core before the tilting sequence begins.

Paramètres techniques et marques de soutien

Paramètres techniques

Paramètres Spécifications industrielles Engineering Standard
Capacité de charge nominale 50,000 kg (50 Tons) Heavy Industrial Grade
Tilting Angle 0° to 90° Precision Controlled
Tilting Time 120 – 180 Seconds (Adjustable) Soft-Start / Soft-Stop
Hydraulic Drive Dual High-Pressure Cylinders Redundant Safety Valves
Système de contrôle Siemens PLC / Wired Remote EMI-Shielded
Safety Clearance Integrated Perimeter Fencing ISO 13849 Compliant

Strategic Industrial Applications

The deployment of the 50-ton Hydraulic Tilter is a standard requirement for Tier-1 facilities in:

  • Energy & Nuclear: Tilting massive transformer cores and reactor components.

  • Steel & Heavy Industry: Positioning large steel coils or heavy mold bases.

  • Aerospace Manufacturing: Orienting large-scale fuselage sections or tooling jigs.

Note: This equipment is strictly designed for industrial load manipulation and is not for use in civil or passenger environments.

Why Choose This Heavy-Duty Tilting Solution?

  1. Redundant Safety Systems: Equipped with hydraulic velocity fuses and mechanical locks to hold the load securely at any angle in the event of a power failure.

  2. Reinforced Structural Frame: The heavy-gauge steel frame (featured in the project photo) is stress-relieved to ensure long-term geometric accuracy under 50-ton loads.

  3. Bespoke Platform Design: The platform interface can be customized with rollers, clamping units, or specialized fixtures to suit specific transformer core geometries.

Soutien aux marques

Nos machines basculantes adoptent des composants de première qualité, importés et de marque nationale, pour la commande électrique, les pièces pneumatiques, hydrauliques et mécaniques.
1. Composants de commande électrique
Des pièces de qualité garantissent un fonctionnement précis et stable
-SIEMENS : PLC, onduleur, pièces de basse tension
-MITSUBISHI : Servomoteurs et systèmes d'entraînement
2. Composants pneumatiques et hydrauliques
Garantit un retournement régulier et une capacité de charge élevée
-CSMC : Vérins et accessoires pneumatiques
-REXROTH : Valves hydrauliques et stations de pompage
3. Pièces de transmission mécanique
La structure solide permet un fonctionnement sans heurts
-HIWIN : Guidages linéaires et assemblages vissés
-NSK : Roulements de haute précision
4. Pièces de distribution basse tension
-CHINT/DELIXI : Disjoncteurs et interrupteurs
-EATON : Composants de sécurité et de distribution

Exécution du projet et réalisations

Détails de la mise en œuvre

Exécution et réalisations

For a professional electrical equipment manufacturing enterprise specializing in power transformer production, we delivered a 50-Ton Heavy-Duty Hydraulic Tilter, custom-built for ultra-heavy transformer core flipping, positioning and processing operations. Replacing traditional crane-assisted manual turnover and segmented handling methods, this heavy-load hydraulic tilting solution solves core industry pain points including unbalanced flipping, low positioning accuracy, high damage risk and low production efficiency, realizing safe, precise and high-efficiency turnover processing for large transformer core workpieces.
1. Ultra-Heavy Load Custom Structural Design
Transformer cores feature ultra-heavy weight, large overall volume and high structural precision requirements. Ordinary tilting equipment and conventional cranes cannot bear 50-ton super-heavy load, and are prone to structural deformation, stress imbalance and severe shaking during turnover. This customized heavy-duty hydraulic tilter adopts thickened full steel welded structure and optimized integral bearing design, with super structural rigidity and anti-deformation performance. It perfectly adapts to ultra-heavy transformer core processing working conditions and meets strict power equipment manufacturing standards.
2. Precision Hydraulic Flipping Boosts Production Efficiency
Traditional transformer core turnover requires multi-person collaborative hoisting, repeated calibration and long positioning time, resulting in extremely long processing cycles and restricted production capacity. The synchronous hydraulic driving system realizes one-button automatic 90° stable flipping and accurate angle locking without repeated adjustment. It improves transformer core processing efficiency by over 80%, greatly accelerating workpiece assembly, detection and finishing cycles.
3. Stable Stress Balance & Zero Workpiece Damage
Transformer cores are precision electrical components with extremely strict requirements for integral structural stability. Traditional hoisting flipping easily causes local stress concentration, component displacement, insulation layer damage and core deformation, leading to high rework and rejection rates. The hydraulic tilter achieves full-area uniform bearing and smooth impact-free flipping, realizing zero deformation and zero structural damage to ultra-heavy transformer cores and ensuring product qualification rate.
4. Dramatic Labor Saving & Risk Elimination
Ultra-heavy core turnover traditionally requires multiple professional workers for rigging fixing, hoisting coordination and safety monitoring, with huge labor investment and high operational risks. This automated 50-ton hydraulic tilter supports fonctionnement indépendant d'une seule personne. It simplifies complex heavy-load operating procedures, eliminates human error and safety hazards, and maintains stable high-frequency production output.
5. Industrial-Grade Durability for Heavy-Duty Production
Designed for long-term high-intensity and super-heavy load cyclic operation, the equipment is equipped with high-pressure wear-resistant hydraulic components, overload protection, hydraulic self-locking and emergency stop interlock systems. It features stable power output, strong safety redundancy and low failure rate, fully adapting to continuous high-load operation in transformer manufacturing workshops and reducing long-term maintenance costs.
Avantages globaux du projet
After official commissioning and operation, the client’s ultra-heavy transformer core processing efficiency increased by 80%+, with significant labor cost savings and zero quality or safety accidents. The entire heavy-load flipping and positioning process achieved standardization, automation and high-precision operation, effectively upgrading production capacity and core product quality for power equipment manufacturing.

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