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Zhongxin General Electric Begins Production of 40 Custom Transformers for a Major Energy Storage Project

Assembled 5250kVA/37kV transformer prototype waiting for factory testing at Zhongxin General Electric
Sichuan Zhongxin General Electric Energy Co., Ltd. has started production on the first batch of 40 transformers for a large battery energy storage station. Each unit is rated at 5250 kVA/37kV. This capacity falls outside China's standard transformer specifications, so our engineering team designed and built new molds and core structures specifically for this order

Built for the Demands of Energy Storage

Transformers in energy storage stations work under harder conditions than transformers in a typical grid application. Power flows in both directions as the station charges and discharges. The power conversion system (PCS) generates harmonic currents that add extra heating to the windings. Frequent charge-discharge cycles also push the transformer through fast temperature swings, again and again.

Our design team accounted for all three factors from the start. The result is a transformer built to run reliably through bidirectional loading, harmonic stress, and repeated thermal cycling.

Custom Engineering for a Non-Standard Capacity

A 5250 kVA/37kV rating doesn’t match China’s national standard capacity table. To build this order, Zhongxin General Electric redesigned the winding casting molds and the core structure from scratch, then built new tooling to match. Our in-house design and production system let us make this kind of change without relying on outside suppliers. Our quality management system then runs the full set of type tests needed to confirm the new design meets the operating standards for energy storage transformers.

From the Workshop Floor

The following photos follow one transformer through the production process, from winding to final testing.

Worker winding a high-voltage coil at Zhongxin General Electric factory
A worker winds a high-voltage coil by hand, one of the first steps in building each transformer.
Workers securing the high-voltage winding mold before resin casting
The team fixes the high-voltage winding mold in place, ready for the drying and casting stages ahead.
High-voltage winding entering the hot-air drying chamber
The high-voltage winding waits to enter the hot-air chamber, where it will cycle through a controlled drying process.
Low-voltage winding after hot-air drying, resting before epoxy resin casting
After hot-air drying, the low-voltage winding rests for 12 hours before the epoxy resin casting begins.
Winding after mold removal, ready for surface grinding
Once removed from the mold, the winding waits for a worker to grind and smooth its surface.
Finished low-voltage windings set aside after polishing
Polished low-voltage windings sit in a row, finished and ready for the next stage.
High-voltage winding resting on the floor before core stacking
A high-voltage winding rests on the floor to cool before the silicon steel sheet stacking begins.
Workers pre-assembling silicon steel sheets for the transformer core
Workers stack silicon steel sheets by hand, building up the pre-assembled sections of the core.
Pre-assembled silicon steel core limb
A finished core limb shows the layered silicon steel sheets after pre-assembly.
Workers stacking the remaining core sections around the fitted windings
With the windings fitted in place, workers stack the remaining sections of the core around them.
Transformer prototype ready for test bay evaluation
A finished transformer prototype waits for a round of tests, with an independent lab set to review the results afterward.
Prefabricated energy storage enclosure with four PCS units, holding the first transformer prototype
The first transformer prototype sits inside a prefabricated storage enclosure equipped with four PCS units.

Looking Ahead

This 40-unit order marks another step in Zhongxin General Electric’s work in the energy storage sector. With an in-house design and production system and a full testing program in place, the company plans to keep building transformers matched to the specific needs of large-scale storage projects.

The first batch is now moving through testing, with delivery and site installation to follow. We will share updates on shipping details, the remaining manufacturing process for this order, testing results, and on-site commissioning as the project moves forward. Stay tuned for the next report.

For more information, visit our case studies page, or browse recent updates in our Company News section.

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