Revolutionizing Transformer Brazing: How Oxyhydrogen Technology Solves Industry Challenges

From enhanced joint reliability in copper to cleaner, safer welding, the future of transformer manufacturing is here.

In the cutthroat industry of producing power transformers, equipment life and reliability hinge on the quality of copper-to-copper brazing alone. World-class transformer leader Jinpan Electric, owner of the world’s largest transformer workshop, has set the pace for the industry to adopt oxyhydrogen brazing technology in resolving long-term industry issues. Its success testifies to how this innovative solution, powered by oxyhydrogen generators and high-tech HHO welding machines, is transforming the way it’s made.

Among the most critical production problems of the transformer has been creating strong, porosity-free joints in high-voltage assembly. Conventional acetylene brazing commonly introduced microscopically small gas bubbles that led to weakening of the joint. “We had a 3.5% reject rate on our 220kV transformer bushings,” says Wang Li, QA Director at Jinpan. “Since last year, with the HHO generator welders in place, that rate fell to a mere 0.6%.” A hydrogen-oxygen flame, with a burning point of 2800 °C, destroys carbon contamination common in gas-brazed joint porosity.

Heat distortion has also been a significant concern, particularly when working with sensitive winding components. An HHO welding machine’s concentrated needle flame produces a heat-affected zone of just 3mm, compared to acetylene torches, which have a zone of 8–10mm. This precision has allowed Jinpan to maintain the tight ±0.1 mm dimensional tolerances required for top-of-the-line transformers. “We’ve eliminated warping in our thin copper laminations,” comments Production Director Chen Wei. “The ability to braze adjacent paper insulation without burning has been a real boon to our quality control.”

Quite possibly the most groundbreaking benefit has been maintaining transformer oil cleanliness—traditional brazing methods left behind flux residues and carbon particles, which required extensive filtration. Jinpan’s oil analysis reports show a 70% reduction in particulate contamination since implementing a clean welding procedure using oxyhydrogen gas generators. “We’ve reduced our post-braze oil processing time from 3 hours to just 45 minutes per unit,” Chen Wei adds. The HHO combustion product of water vapor leaves no conductive residues behind that could lead to partial discharge.

The operating advantages extend beyond quality improvements. Jinpan’s brazing energy costs have decreased 52% from its previous acetylene system. The elimination of gas cylinder storage has also enhanced workplace safety and freed valuable production floor space. “What surprised us most was the reduction in labor requirements,” says Wang Li. “We’ve redeployed two full-time staff who previously did nothing but post-braze cleaning.”

Centralized Oxyhydrogen Gas Supply: Efficient & Safe for Multi-Station Workflows

To further maximize production, Jinpan has invested in a Centralized Oxyhydrogen Gas Supply System that links an oxyhydrogen generator unit to several brazing stations through a regulated distribution system. With this configuration, uniform gas quality, stable pressure, and enhanced flame consistency are provided for all workstations, which maximizes HHO brazing efficiency at the factory level.

In contrast to frequent cylinder replacement and manual control of decentralized acetylene systems, a centralized HHO gas supply system minimizes handling danger and simplifies daily functions. On-site demand is answered by the generator’s production of hydrogen and oxygen gas by water electrolysis, providing clean energy for welding directly at every workstation with real-time flow measurement.

Every outlet is equipped with safety check valves, automatic shut-offs, and backfire prevention systems, so welding safety is never compromised, even in high-volume operations. This configuration not only shields personnel but also provides consistent flame characteristics essential to precision brazing.

Furthermore, centralizing the gas supply also minimizes maintenance requirements, eliminates the logistics of handling multiple cylinders, and allows for better space utilization in large-scale transformer manufacturing facilities.

Conclusion

Even when the HHO welding machine brought the best-class work in the Jinpan case, accommodation was never harder. Its factory’s production unit was made to fall below proficiency in flame handling technique after a six-week brutal retraining regimen. Even the quality inspection routine was altered based on the visible differences that come with using HHO-brazing.

For transformer makers considering the changeover, Jinpan’s experience serves as a lesson. The technology has unique benefits for high-voltage equipment where the reliability of joints is paramount, and in plants with environmental regulation as a top priority. As Chen Wei summarizes, “Oxyhydrogen brazing has solved three of our longest-standing quality issues while lowering operating expenses – that’s a seldom-seen combination in manufacturing.”

While the power industry demands more reliability and sustainability, oxyhydrogen technology is not just an alternative brazing process – it is turning into a strategic opportunity for pioneering manufacturers like Jinpan Electric. Its success shows how pioneering industrial welding technology can spur quality improvement and enhanced operational efficiency.