Brand: Pahsa Enerji
Transformer Cable Box Manufacturing Process
The transformer cable box is a crucial component that ensures safe and insulated power input and output connections for the transformer. Electrical safety, sealing, and mechanical strength are the primary focus of the manufacturing process.
1. Design and Technical Preparation
The manufacturing process begins with the customer receiving the transformer connection type (low voltage/high voltage), cable cross-section, bushing size, and installation details.
Box dimensions, connection directions, and sealing surfaces are 3D modeled in a CAD environment. Cable entry angles and water drainage points are also determined during the design phase.
2. Material Selection and Cutting
S235JR grade steel sheet is generally used, or in special cases, stainless steel/galvanized sheet. The material thickness is determined by the box's size and the environmental conditions in which it will be used.
Cutting is performed with precise tolerances on CNC laser or plasma machines.
3. Bending and Forming
The cut sheet metal is bent to the specified angle and shape using hydraulic press brakes. This step is crucial for the accuracy of the box body dimensions and ease of assembly.
4. Welding and Assembly
The bent parts are joined using MIG/MAG welding. The body, cover, flanges, and connecting parts of the cable box are ground and surface-finished after welding.
Hinges, locks, and sealing slots are installed at this stage to ensure easy opening and closing of the cover.
5. Drilling and Accessory Installation
Cable gland holes, grounding points, oil level indicators, and terminal connection openings are machined onto the box. Threading (tapping) is performed in the required areas.
All dimensions and positions are machined on CNC-controlled machines to ensure perfect fit.
6. Leakage and Pressure Tests
After assembly, the cable box is subjected to a leakage test under air pressure. Welded surfaces are checked for leaks.
Sealed covers are tested for IP protection class (e.g., IP54 or IP55).
7. Surface Cleaning and Painting
Surfaces are first sandblasted (to SA 2.5 standard). Industrial primer and a top coat of paint are then applied to enhance resistance to outdoor conditions.
Galvanized or electrostatic powder coating is also available upon request.
8. Final Inspection and Shipping
Once production is complete, dimensions, paint thickness, and leakage are checked. Boxes that pass all approvals are packaged in protective packaging and prepared for shipping.