Empowering Local Manufacturing
with In-House Tooling for Three-Phase Laminations
Innovative solutions that reduce volume, enhance efficiency, and lower transportation costs.
Industry Focus:
Transformer Manufacturing
Client Challenge:
Three-phase laminations (EI) were only available via imports. As an alternative, customers used strip laminations arranged in the shape of EI. However, this caused gaps in the transformer core, leading to performance losses. The client approached us to develop a localized supply of three-phase laminations in India.
Project Timeline:
~6–7 years ago
Execution Timeframe:
3 months
Solution Provided
Our Tool Room innovation became the key differentiator in solving this challenge:
- We invested in and developed specialized tooling to manufacture three-phase laminations in-house.
- By identifying a specific subset of international standard proportions, we discovered that the E-lamination window could directly be used to create the I-lamination without any wastage.
- Using this insight, we created precision tooling at Benaka’s in-house tool room that enabled us to produce three-phase laminations with the same standard processes used for single-phase EI laminations.
Special Material & Technical Context
A three-phase transformer steps up or steps down voltages in three-phase electrical systems and is preferred over single-phase transformers due to efficiency and size advantages.
The laminations for three-phase transformers differ significantly from single-phase designs, primarily due to the equal limb dimensions. Traditionally, there were two manufacturing approaches:
Modify Single-Phase Laminations
Performing an additional operation on single-phase laminations to make all three limbs equal.
Disadvantage: Material wastage and higher labour costs.
Arrange Strip Laminations
Using strips to emulate the EI shape for flexibility in tooling.
Disadvantage: Multiple joins in the core, resulting in performance inefficiencies.
The result?
This innovation helped the client significantly reduce dependency on imports by enabling the local production of three-phase laminations. By eliminating material wastage and streamlining the manufacturing process, we were able to deliver a cost-effective and efficient solution. The laminations produced were not only high in quality but also offered improved transformer performance by eliminating the gaps caused by traditional strip lamination methods. Through the development of precision tooling in our in-house tool room, we transformed a challenging requirement into a scalable, sustainable, and high-performance solution.
Today, Benaka manufactures a comprehensive range of international sizes for three-phase laminations, including EI-100, EI-125, EI-150, EI-190, EI-200, EI-250, EI-300, and EI-350. To support seamless transformer assembly, we also provide nylon bobbins and clamps designed to perfectly complement these laminations.
Related Products
