INTELLIGENT AUTOMATION AND DIGITAL TRANSFORMATION IN TRANSFORMER MANUFACTURING: AN APPLIED STUDY OF THE TRAFO ULC PROTOTYPE AT FLEX INDUSTRIES

Abstract

Digital transformation and Industry 4.0 principles have driven profound structural changes in global manufacturing, driving the integration of information technology and physical processes. This study presents the development and validation of the TRAFO ULC prototype, an automated system designed for the winding and application of high-insulation tape on high-frequency transformers, developed by B&Z Serviços de Automação in partnership with Flex Industries. The project incorporates embedded artificial intelligence (IAE) and cyber-physical systems (CPS) to optimize production efficiency, reduce errors, and eliminate ergonomic risks. The methodology adopted combined agile project management practices (Scrum and PMI) with applied research and experimental development, using 3D modeling, PLC control, and intelligent algorithms to coordinate sensors and actuators. The results demonstrated a 99.85% increase in process compliance, a reduction in failures from 6.7% to 0.5%, and the elimination of absences due to occupational hazards. These advances demonstrate that intelligent automation is a strategic driver of competitiveness and sustainability in the Manaus Industrial Hub (PIM), directly contributing to technological innovation, improved production efficiency, and improved working conditions in regional industrial plants.

DOI: https://doi.org/10.56238/edimpacto2025.086-001