{"id":14656,"date":"2025-09-02T14:44:10","date_gmt":"2025-09-02T12:44:10","guid":{"rendered":"https:\/\/autforce.com\/?post_type=referenz&#038;p=14656"},"modified":"2026-03-12T08:32:09","modified_gmt":"2026-03-12T07:32:09","slug":"automated-quality-inspection-for-transformer-winding-conductors","status":"publish","type":"referenz","link":"https:\/\/autforce.com\/en\/referenz\/automated-quality-inspection-for-transformer-winding-conductors\/","title":{"rendered":"Automated quality inspection for transformer winding conductors"},"content":{"rendered":"<div class=\"wp-block-autforce-area\">\n    \n    \n    <div class=\"container free\" style=\"padding-top: 80px; padding-bottom: 80px; \">\n        \n        \n\n<div class=\"wp-block-columns is-layout-flex wp-container-core-columns-is-layout-9d6595d7 wp-block-columns-is-layout-flex\">\n<div class=\"wp-block-column is-layout-flow wp-block-column-is-layout-flow\">\n<h2 class=\"wp-block-heading\">The project<\/h2>\n\n\n\n<p>For our customer in the energy technology industry, we implemented an <strong>automated testing system for quality control of insulated winding conductors<\/strong> used in transformers. The aim was to <strong>reliably detect damage to the insulation<\/strong> and thus ensure the quality of the subsequent windings. <\/p>\n\n\n\n<!--more-->\n\n\n\n<p>The inspection system is designed as a stand-alone unit with its own control system and can be flexibly integrated into existing production lines. All sides of the conductor are captured by a camera system with four line scan cameras arranged in perspective. AI-supported anomaly detection automatically identifies even the smallest damage. When defects are detected, the system stops the feed, visually displays the defect, and allows the operator to check it directly.   <\/p>\n<\/div>\n\n\n\n<div class=\"wp-block-column is-layout-flow wp-block-column-is-layout-flow\" style=\"flex-basis:5%\"><\/div>\n\n\n\n<div class=\"wp-block-column is-layout-flow wp-block-column-is-layout-flow\">\n<figure class=\"wp-block-image size-large\"><img decoding=\"async\" src=\"https:\/\/autforce.com\/wp-content\/uploads\/2025\/09\/21036_Leiterkontrolle_grafische_Darstellung_EN-1024x1024.webp\" alt=\"Graphical representation of optical quality control for winding conductors. The conductor is located in the center, with a bar light and a high-resolution camera to the left, right, above, and below the conductor.  \" class=\"wp-image-14639\" title=\"Graphical representation of automated optical quality control\"\/><\/figure>\n<\/div>\n<\/div>\n\n\n            <\/div>\n\n    <\/div>\n<div class=\"wp-block-autforce-area\">\n            <div class=\"background\" style=\"background: #f4f5f7; height: 100%\"><\/div>\n    \n    \n    <div class=\"container free\" style=\"padding-top: 80px; padding-bottom: 80px; \">\n        \n        \n\n<div class=\"wp-block-columns is-layout-flex wp-container-core-columns-is-layout-9d6595d7 wp-block-columns-is-layout-flex\">\n<div class=\"wp-block-column is-layout-flow wp-block-column-is-layout-flow\">\n<figure class=\"wp-block-image size-large\"><img loading=\"lazy\" decoding=\"async\" width=\"1024\" height=\"576\" src=\"https:\/\/autforce.com\/wp-content\/uploads\/2025\/08\/Anomalieerkennung_Isolation_Leiter-1024x576.webp\" alt=\"User interface of the AI-based anomaly detection software used to inspect isolated winding conductors.\" class=\"wp-image-14636\" title=\"Anomaly detection with AI\" srcset=\"https:\/\/autforce.com\/wp-content\/uploads\/2025\/08\/Anomalieerkennung_Isolation_Leiter-1024x576.webp 1024w, https:\/\/autforce.com\/wp-content\/uploads\/2025\/08\/Anomalieerkennung_Isolation_Leiter-300x169.webp 300w, https:\/\/autforce.com\/wp-content\/uploads\/2025\/08\/Anomalieerkennung_Isolation_Leiter-768x432.webp 768w, https:\/\/autforce.com\/wp-content\/uploads\/2025\/08\/Anomalieerkennung_Isolation_Leiter.webp 1500w\" sizes=\"auto, (max-width: 1024px) 100vw, 1024px\" \/><\/figure>\n<\/div>\n\n\n\n<div class=\"wp-block-column is-layout-flow wp-block-column-is-layout-flow\" style=\"flex-basis:5%\"><\/div>\n\n\n\n<div class=\"wp-block-column is-layout-flow wp-block-column-is-layout-flow\">\n<h2 class=\"wp-block-heading\">Keyfacts<\/h2>\n\n\n\n<div style=\"height:20px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<ul class=\"sflist-round wp-block-list\">\n<li><strong>Automated quality inspection<\/strong> for insulated winding conductors<\/li>\n\n\n\n<li><strong>AI<\/strong><strong>&#8211;<\/strong><strong>supported error detection<\/strong> for maximum reliability<\/li>\n\n\n\n<li><strong>Camera system with 360\u00b0 coverage<\/strong> of the entire surface<\/li>\n\n\n\n<li><strong>Independent, flexibly integrable test unit<\/strong><\/li>\n\n\n\n<li><strong>Automatic process stop and visual error display<\/strong><\/li>\n\n\n\n<li><strong>Storage and traceability<\/strong> of all test results<\/li>\n<\/ul>\n<\/div>\n<\/div>\n\n\n            <\/div>\n\n    <\/div>\n<div class=\"wp-block-autforce-area\">\n    \n    \n    <div class=\"container free\" style=\"padding-top: 80px; padding-bottom: 80px; \">\n        \n        \n\n<div class=\"wp-block-columns is-layout-flex wp-container-core-columns-is-layout-9d6595d7 wp-block-columns-is-layout-flex\">\n<div class=\"wp-block-column is-layout-flow wp-block-column-is-layout-flow\">\n<h2 class=\"wp-block-heading\">Realization<\/h2>\n\n\n\n<p>The testing system guides each insulated winding conductor through a compact camera housing, where <strong>four high-resolution cameras<\/strong> capture images of all sides of the conductor. The image data is evaluated in<strong> real time<\/strong>: an <strong>AI-supported system<\/strong> automatically detects deviations and damage, even if they are very small or difficult to see. <\/p>\n\n\n\n<p>As soon as a defect is detected, the system stops feeding and shows the operator the exact position of the defect on a user interface. The operator can then check the conductor and either approve it or reject it. In addition, all images and test results are stored for <strong>complete traceability<\/strong>.  <\/p>\n\n\n\n<p>Thanks to the modular design, flexible integration into existing production lines, and reliable AI detection, the customer was able to significantly optimize the quality assurance of its winding processes and considerably reduce the amount of manual inspection work required.<\/p>\n\n\n<a href=\"https:\/\/autforce.com\/pruefsysteme\/optische-qualitaetskontrolle\/\" target=\"_self\" style=\"margin-top: 40px; float: none\" class=\"wp-block-autforce-round-button\">More about optical quality control<\/a>\n<\/div>\n\n\n\n<div class=\"wp-block-column is-layout-flow wp-block-column-is-layout-flow\" style=\"flex-basis:5%\"><\/div>\n\n\n\n<div class=\"wp-block-column is-layout-flow wp-block-column-is-layout-flow\">\n<figure class=\"wp-block-image size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"566\" height=\"682\" src=\"https:\/\/autforce.com\/wp-content\/uploads\/2025\/08\/Leiterkontrolle_freigestellt.webp\" alt=\"Automated optical inspection system for checking insulated winding conductors\" class=\"wp-image-14632\" title=\"visual quality control\" srcset=\"https:\/\/autforce.com\/wp-content\/uploads\/2025\/08\/Leiterkontrolle_freigestellt.webp 566w, https:\/\/autforce.com\/wp-content\/uploads\/2025\/08\/Leiterkontrolle_freigestellt-249x300.webp 249w\" sizes=\"auto, (max-width: 566px) 100vw, 566px\" \/><\/figure>\n<\/div>\n<\/div>\n\n\n            <\/div>\n\n    <\/div>\n<div class=\"wp-block-autforce-area\">\n            <div class=\"background\" style=\"background: #f4f5f7; height: 100%\"><\/div>\n    \n    \n    <div class=\"container image-right\" style=\"padding-top: 80px; padding-bottom: 80px; \">\n        \n        \n\n<div class=\"wp-block-column is-layout-flow wp-block-column-is-layout-flow\">\n<h2 class=\"wp-block-heading\">Do you also need optical quality control?<\/h2>\n\n\n\n<p>At AUTFORCE, we specialise in <strong>testing systems and industrial software<\/strong>. Get in touch with us. Together we will find the best solution for your task!<\/p>\n\n\n\n<div style=\"height:20px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<p><strong>Christian Hanbauer<\/strong><br\/>Expert Test Systems<br\/><a href=\"tel:+4366488710250\">+43 (664) 88 71 02 50<\/a><br\/><a href=\"mailto:christian.hanbauer@autforce.com\">christian.hanbauer@autforce.com<\/a>   <\/p>\n\n\n\n<ul class=\"wp-block-social-links has-small-icon-size has-visible-labels is-layout-flex wp-block-social-links-is-layout-flex\"><li class=\"wp-social-link wp-social-link-linkedin  wp-block-social-link\"><a href=\"https:\/\/www.linkedin.com\/in\/christian-hanbauer\/\" class=\"wp-block-social-link-anchor\" target=\"_blank\" rel=\"noopener\"><svg width=\"24\" height=\"24\" viewBox=\"0 0 24 24\" version=\"1.1\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\" aria-hidden=\"true\" focusable=\"false\"><path d=\"M19.7,3H4.3C3.582,3,3,3.582,3,4.3v15.4C3,20.418,3.582,21,4.3,21h15.4c0.718,0,1.3-0.582,1.3-1.3V4.3 C21,3.582,20.418,3,19.7,3z M8.339,18.338H5.667v-8.59h2.672V18.338z M7.004,8.574c-0.857,0-1.549-0.694-1.549-1.548 c0-0.855,0.691-1.548,1.549-1.548c0.854,0,1.547,0.694,1.547,1.548C8.551,7.881,7.858,8.574,7.004,8.574z M18.339,18.338h-2.669 v-4.177c0-0.996-0.017-2.278-1.387-2.278c-1.389,0-1.601,1.086-1.601,2.206v4.249h-2.667v-8.59h2.559v1.174h0.037 c0.356-0.675,1.227-1.387,2.526-1.387c2.703,0,3.203,1.779,3.203,4.092V18.338z\"><\/path><\/svg><span class=\"wp-block-social-link-label\">LinkedIn<\/span><\/a><\/li><\/ul>\n\n\n\n<div style=\"height:40px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<p><strong>Get a non-binding initial assessment now:<\/strong><\/p>\n\n\n<noscript class=\"ninja-forms-noscript-message\">\n\tNotice: JavaScript is required for this content.<\/noscript>\n<style>\n\n        \/* PLUGIN WIDE STYLES *\/\n    \n        .nf-form-content .nf-field-container .field-wrap {\n                                    border-width:0px;\n                               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