An automated core rolling machine for making the metering unit’s current transformer

Abstract

The advent of automation has revolutionized various industries by simplifying complex processes, enhancing efficiency, and reducing production time. However, many developing countries still rely on manual labour, resulting in lower production rates and reduced competitiveness in the global market. This study focuses on the challenges faced by Tanzania's electrical equipment company (TANELEC) in the production of metering units, specifically the laborious and hazardous task of rolling the core steel for the units' current transformer (CT). Manual processes often lead to dimensional inaccuracies and gaps in the rolled core, causing a significant number of tested metering units to be deemed unqualified. Consequently, the industry struggles to meet customer demands effectively. The research findings emphasize the urgent need for automating the core rolling process for metering units' CT, which became the primary objective of this study. Employing a qualitative research approach and utilizing the agile methodology, specifically the Extreme Programming agile method, the study aimed to gain a comprehensive understanding of the current manual process. The outcome of the study is a machine capable of intelligently accepting and rolling the required ferromagnetic iron material, with users able to input desired dimensions and quantities of cores. This development has significantly increased TANELEC's production capacity, enabling the manufacturing of up to sixty cores per hour and alleviating the production burden. As a result, the company can now meet customers' demands promptly.