COMMENT Transforming the future
Ales Bertuzzi, advisory board member of CWIEME Berlin, says the transformer industry has long been considered a niche market, with slow innovation compared to other sectors.
H
owever, evolving energy networks, material advancements and
automation are now forcing the industry to rethink transformer design and functionality. Having spent years in the energy sector, I have witnessed numerous market in North America, where the industry has The drive to reduce carbon emissions and accelerated the transition towards electric energy, with nuclear and renewable sources taking precedence over fossil fuels. This reliable transformers to support modern energy networks.
Despite its crucial role in power distribution, transformer technology remains largely unchanged. Transformers still rely on traditional materials such as copper and silicon steel, both of which are becoming Additionally, transformers suffer from energy losses of between 5-10%, which are There is a huge opportunity to rethink transformer design and innovate beyond current limitations. By collaborating and embracing new technologies, we can accelerate progress and enhance energy reliability.
Material innovations One of the most promising areas for transformer innovation is materials. While silicon steel has long been the industry standard for transformer cores, alternative materials are gaining traction. Amorphous materials, for instance, have been used in specialised applications for years due to their low energy loss properties. Chinese manufacturers have already into their distribution networks, leading the The key challenge is sourcing these materials at scale. Every era has had its steel or oil. Today, we must identify and
6 JUNE 2025 | ELECTRONICS FOR ENGINEERS
future of energy infrastructure. Lithium, once abundant, is now facing of sodium as an alternative. Similarly, as copper prices rise, aluminium is becoming a viable substitute. By embracing new materials and creating economies of scale, we can drive down costs and improve
Introducing automation Historically, the transformer industry has resisted automation due to the the relatively low production volumes. However, this is changing. The demand for transformers is surging, and manufacturers face delivery times of two to three years. This backlog highlights the urgent need for automation to streamline production and meet growing demand.
Automation offers several advantages for greater customisation, ensuring that addresses the critical skills gap in the industry — machine manufacturers must invest in automation to bridge this divide. However, one of the biggest challenges is the automation of transformer production itself. Currently, every machine manufacturer is highly specialised in
automated processes across the entire supply chain. Collaboration between manufacturers could provide a solution, ensuring that automation is implemented holistically rather than in isolated segments. Additionally, 3D printing of transformers, while not feasible anytime soon due to prospect for long-term innovation. In the improve the production process, making transformers more accessible and cost- effective.
Regulatory barriers
One of the primary barriers to automation in the transformer industry is the lack of standardisation across markets. In Europe, effectively creating trade barriers. This fragmentation makes large-scale automation impractical, as manufacturers must produce small batches of varied designs rather than high volumes of standardised units.
If governments were to align their pricing for consumers. Standardisation would enable manufacturers to automate energy providers and end users.
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