Fibre optics enable important digitalisation steps for Hitachi Energy

Ludvika has over 120 years of experience in power transmission innovation. They are experts in the art of moving energy from the source to the point of use. Transformers weighing up to 500 tonnes and shunt reactors the size of truck cabins roll out of the Hitachi Energy factory. The production environment is high-tech - and the digitalisation journey continues.

"Discussions with RISE have opened our eyes to fibre optics as a technology for measuring critical parameters. Fibre optics can provide us with much more information than traditional sensors, and in real time. This is crucial for optimising our processes and taking the next step in digitalisation," says Christos Athanasopoulos, Principal Engineer at Hitachi Energy's Transit R&D department.

Francisco Penayo, R&D specialist at Hitachi Energy:

"To become more data-driven in manufacturing, you need this kind of data. We can't use AI or other machine learning tools without models, and the models are based on data from the manufacturing process."

Fibre optics paves the way for smarter manufacturing

In the manufacture of transformers and high-voltage components, the use of thermocouples for temperature measurement has long been the standard, but fibre optics offers more possibilities. The technology is based on passing light through thin glass fibres, allowing very accurate measurements even in hard-to-reach environments.

As fibre optic sensors are insensitive to electromagnetic radiation, they work well in high voltage applications. In addition to temperature, fibre optic sensors can also measure moisture and vibration. This gives Hitachi Energy a nuanced picture of what is happening in different parts of the production line.

"We use this information to improve our simulation models. This leads to better designs, better test results and ultimately more durable products. If things go well, there are plans to integrate fibre optics directly into our products, for example in transformers and bushings. In this way, we can not only optimise production, but also help our customers to optimise use and operation," says Francisco Penayo.

"RISE has deep knowledge"

Maximilian Patzauer is a researcher and project manager and part of the fibre optics team at RISE. He points out that fibre optic sensors have been around for a long time, but for high voltage products they are still relatively new. According to Patzauer, RISE's role in the collaboration has been very much to open doors and show what is possible - then it is up to Hitachi Energy to choose which solutions to go ahead with.

"Hitachi Energy is a world leader in its products and its manufacturing is very advanced, but with large and expensive processes comes the pressure to make sure nothing breaks. You don't want to put in sensors that could have a negative impact. The customer has to make sure that the digitalisation steps are big enough to make a difference, but at the same time proceed with caution," says Maximilian Patzauer.

Together with RISE, Hitachi Energy has conducted two feasibility studies in which the parties have tested fibre-optic sensors, for example for moisture measurement. Today, the company is working directly with RISE to develop the next generation of fibre optic measurement technology. The RISE team has carried out tests and measurements both on-site at Hitachi Energy in Ludvika and in its own laboratory. RISE has also delivered tailored lectures and workshops on fibre optics for Hitachi.

"RISE has in-depth academic knowledge, is focused on projects and is used to delivering. "We are in direct contact with the experts at RISE and have ongoing discussions. This makes the collaboration both faster and better," says Francisco Penayo of Hitachi Energy.

Fibre optics is an important key

Hitachi Energy in Sweden is currently experiencing strong growth with 7,000 employees, of which almost 5,000 are based in Ludvika. The goal is to have a total of 8,000 employees by 2030. To cope with this growth, we need not only more production capacity, but also more efficient and smarter manufacturing.

"We are investing billions in Ludvika over the coming years. If we are to achieve sustainable growth, we need to make better use of our resources, which means increasing the use of data. Fibre is an important key to this," says Francisco Penayo.