- Conference Article
- 10.1109/pesgm52009.2025.11225417
Digital transformation of the hot-air-circulation drying process for distribution-transformer core-coil assemblies
- Jul 27, 2025
- Gerardo Tamez + 1 more +1
The traditional process of insulation drying in oven chambers with hot air circulation (HAC) is a flexible method that simultaneously can dry a mixture of active parts with different capacities and voltages. The process employs a few empirical recipes with cycle times that are not specific for each design but group active parts in a range of capacities and voltages. The recipes are devised to ensure low levels of moisture in the units with the heaviest and thickest insulation assemblies but carry the disadvantage of unnecessarily extending the cycle for the ones with the lightest insulation assemblies. These recipes consider extra time to cover scenarios when oven doors are repeatedly opened to either put active parts inside the oven or take them out. It is a great challenge to optimize this operation if controlled manually. Digital transformation of drying process is required to optimize cycle times, ensure low moisture levels, minimize over exposure of active parts to heat, and save energy. Moisture content in the insulation is the key parameter that must be known if operation of the drying process is to be controlled, but there is no sensor that can measure it directly. Also, the heating of the active parts is not uniform, so moisture removal is not uniform either. Combining the principles of heat and mass transfer with experimental data, it is possible to calculate moisture content in the active part insulation if parameters like time, temperature, and relative humidity in the oven chamber are measured. Experiments done at manufacturing site and at research laboratory were performed to produce data that allowed to tune up physical parameters like coefficients of moisture diffusion, mass transfer, and heat transfer. In this way, a virtual moisture sensor has been developed and implemented as part of the digital transformation of the drying process with HAC. The devised architecture, the software design, as well as the Internet of Things (IoT) based monitoring system are presented as well as the flow of the digitized data. Examples of graphics used by the staff to monitor the evolution of the drying process parameters are also shown. Finally, some benefits of the digital transformation of the drying process are shown by analyzing a sample of 28 identical active parts that were dried in an oven with HAC.
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