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From welding challenge to 50% higher output with robot welding

Kyte Powertech, an Irish manufacturer of distribution transformers, faced ongoing challenges with finding skilled welders and managing higher health and safety risks as their products grew larger. Their long-standing partnership with Valk Welding has revolutionised their manufacturing process, now with a third installation in place. According to Kyte Powertech, “No other system integrator could give us the guarantees that Valk Welding offered.”

Kyte Powertech

Transformers for critical infrastructure

Kyte Powertech is a manufacturing company specialising in the design and production of oil-filled distribution transformers. Founded in 1977 as Pauwels Trafo Belgium, the company supplies utilities, renewable energy projects and industrial customers in Ireland, the United Kingdom and Europe. From a 17,500 m² production facility, more than 16,000 transformers are produced annually. The product range includes pole- and ground-mounted distribution transformers, compact substations and specialised transformer solutions.

Growing demand, growing challenges

The decision to automate arose from multiple converging challenges. Finding and retaining skilled welders proved increasingly difficult. “We spent a great deal of time training welders who left after a short period. Each time, we started from scratch,” the company explains. Furthermore, working with individual welders inevitably led to variation in quality and the end product. At the same time, transformers are increasing in size. The collaboration with Valk Welding began in 2020 with the installation of the first two robot welding systems. That experience laid a solid foundation for the next steps.

A fully turnkey solution

For the third installation, Kyte Powertech faced additional technical requirements. New technologies had to be integrated, including a torch changeover system to automatically switch to a narrower, curved torch for hard-to-reach weld seams. In addition, an ARC-EYE circular laser scanner for seam tracking was added, as well as an integrated on-torch welding fume extraction solution. This torch-mounted fume extraction solution is a real game changer for us from a health and safety perspective.
“For us, the possibility of a 100% turnkey solution was also decisive. No other system integrator could match this with the delivery guarantees that Valk Welding could provide.”

Smart preparation, smooth implementation

The implementation proceeded exceptionally efficiently thanks to a well-considered approach. Kyte Powertech sent tacked parts in advance to Valk Welding in the Netherlands for the factory acceptance test. This gave Valk Welding ample time to test and resolve complexities beforehand. Thanks to the DTPS offline programming software, production programs were also ready prior to installation.

“The installation was fully completed within the two-week Maintenance shutdown window, with time to spare. On the Monday after the shutdown, we were already welding production products on the new system.”

Up to 50% higher output

The results are concrete. With robot welding, the operator handles assembly and tacking, after which the robot takes over the welding. Whilst the robot is working, the operator is already tacking the next product. In some cases, this has led to an increase in output of as much as 50%.
In addition to higher productivity, the automation directly contributes to safety: prolonged welding times, welding fatigue and repetitive tasks are increasingly becoming a thing of the past. “No employee has lost their job due to automation. We use it to fill gaps and take over high-risk tasks.”

Ready for the future

The energy transition is driving demand for larger transformers. Kyte Powertech is anticipating this with further automation and ultimately wants to weld all products robotically.

www.kytepowertech.com

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