Scalable Assembly System for Switching Drives: Automated Production for Tap Changers
Reliable and safe switching of distribution transformers is a key element of stable power distribution. Modern switching drive systems play a crucial role in this context: they control switching operations precisely, reproducibly, and under demanding environmental conditions. To meet the growing demand for these systems while maintaining the highest quality standards, Maschinenfabrik Reinhausen has expanded its production capacities and, together with Strama-MPS, implemented a new scalable assembly system.
The system was installed at the Regensburg site and is designed for long-term growth. The project combines product development, design for automation, and modular manufacturing concepts with integrated testing and digital traceability.
Challenge: Product Variants, Standards, and Growth
As demand for tap changers continues to increase, so do the requirements for production depth, testing processes, and documentation. Maschinenfabrik Reinhausen required an assembly line capable of handling multiple variants of a switching drive system, integrating IEC-compliant testing processes, and ensuring complete traceability of all relevant product and process data. At the same time, the solution needed to allow for increasing production volumes without requiring fundamental modifications to the system.
“For us, it was clear from the very beginning that the system must keep pace with our growing market and remain capable of delivering high performance in the long term,” says Andreas Kerscher, Project Manager at Maschinenfabrik Reinhausen.
Scalable Line Concept and Design for Automation
Strama-MPS was responsible for the design and implementation of the linked assembly line and contributed its extensive expertise in automating complex assembly and testing processes from an early stage.
A central approach was design for automation: together with Maschinenfabrik Reinhausen, the product was further developed specifically to enable automated, reliable, and economically efficient assembly.
The assembly system features a modular design and was built for scalability from the outset. The initial production volume in the four-digit range can be increased several times over within just a few years through relatively simple expansions. Critical bottleneck stations are designed so they can be duplicated if required. Additional automated stations and extended shift models allow flexible adaptation to rising production volumes.
“The close technical coordination enabled us to optimally align product and process. Our task was to implement the complex manufacturing processes efficiently, scalably, and in compliance with standards – the partnership with Maschinenfabrik Reinhausen was a key factor in the project’s success. ”
Linked Assembly Line with Integrated Testing Processes
The implemented assembly system is designed as a linked production line with a workpiece carrier system, ensuring a continuous material flow through all production stages. In upstream areas, key assemblies such as the interrupter unit, gearbox, and contact rods are pre-assembled before being transferred to the main assembly process.
The line combines automated processes—including screw fastening, hot riveting, and laser marking—with ergonomically designed manual workstations. This approach allows different levels of automation to be combined efficiently while maintaining flexibility for product variants.
A particular focus lies on integrated quality assurance. A comprehensive camera inspection system checks the vacuum interrupter cell and ensures that safety-relevant features are reliably detected. Additional tests include torque measurements, leak tests, and a high-voltage test at 14 kV DC. All testing processes are fully integrated into the assembly workflow, ensuring consistently high product quality.
Digital Integration and Full Traceability
As this is a safety-critical product, complete documentation of all production and testing steps is essential. Strama-MPS integrated the system into the existing IT landscape of Maschinenfabrik Reinhausen. Process and test data are transferred to SAP and processed further there.
This ensures full batch and component traceability. At the same time, the system integration supports production control and material supply, including connected Kanban processes.
Regional Collaboration as a Project Factor
By installing the system in Regensburg, Maschinenfabrik Reinhausen is strengthening its site and investing in a modern and high-performance production infrastructure. The geographical proximity to Strama-MPS in Straubing proved to be an additional advantage during the project phase. Coordination could take place quickly, while tests and adjustments were implemented efficiently.
Specialists from Maschinenfabrik Reinhausen were closely involved during installation and commissioning from an early stage. Throughout the project, both partners collaborated on equal terms and contributed their respective expertise.
“The proximity of our locations and the close cooperation significantly facilitated the implementation of the system. Each partner was able to contribute their strengths – which was decisive for the project’s success.”
Efficient, Scalable, and Future-Proof
The new high-voltage assembly system enables the production of modern switching drive systems with high variant flexibility, integrated quality assurance, and complete digital traceability. Through design for automation, a modular line structure, and strategically scalable bottleneck stations, the solution is prepared for future increases in production.
“With the new line, we have not only implemented highly efficient production but also created a solid foundation for further growth,” emphasizes Michael Falter.
The combination of technical implementation expertise, structured project execution, and close partnership positions Strama-MPS as a reliable partner for demanding assembly systems in the energy sector.