Automotive Manufacturing Plant Power Distribution Upgrade
Complete MV/LV power distribution system upgrade for a 200,000 sqm greenfield automotive manufacturing plant. GOHO delivered a full-scope solution including KYN28 medium-voltage switchgear, GCK low-voltage withdrawable switchgear, MNS motor control centers, and 2000kVA distribution transformers — achieving 99.99% uptime and 18% energy cost savings.
Full-Scope Power Infrastructure for a New Automotive Plant
This greenfield automotive manufacturing facility in Central China required a complete medium-voltage and low-voltage power distribution system capable of supporting high-precision production lines, welding robots, CNC machining centers, and paint shop operations. The client, a leading automotive OEM, demanded exceptional reliability, power quality, and scalability for future expansion.
GOHO was selected as the primary power distribution equipment supplier based on our comprehensive product portfolio, engineering capabilities, and proven track record in industrial manufacturing projects. Our scope included the design, manufacturing, testing, and on-site commissioning of the entire MV/LV distribution system.
The project featured a dual-feed redundant design with automatic transfer switching, active power factor correction, and intelligent power monitoring throughout the plant. Our GCK withdrawable switchgear lineup was chosen for its high reliability, ease of maintenance, and modular expandability — critical factors for a facility planning a second-phase expansion.
- Complete MV/LV distribution system from a single manufacturer
- Redundant dual-power feed with automatic transfer for maximum uptime
- Intelligent power monitoring and energy management system
- GCK withdrawable switchgear for easy maintenance and expansion
- Active harmonic filtering for welding robot and CNC loads
- Factory acceptance testing before shipment with client witness
Project at a Glance
Three Critical Challenges We Solved
Automotive manufacturing demands the highest levels of power reliability and quality. Every minute of downtime costs thousands in lost production. Here’s what we were up against.
High Reliability Requirement
The production lines required 99.99% uptime — less than 53 minutes of total downtime per year. Any unexpected power interruption to welding, stamping, or assembly lines would cause massive production losses and potential equipment damage. The system needed full redundancy with automatic failover.
Power Quality for Precision Equipment
Welding robots, CNC machining centers, and servo-driven production lines generate significant harmonic distortion and require ultra-stable voltage. Poor power quality would cause production defects, equipment malfunctions, and shortened equipment lifespan. Harmonic mitigation was essential.
Future Expansion Flexibility
The plant was designed with a planned second-phase expansion that would increase capacity by 50%. The power distribution system needed to be modular and scalable, allowing for easy addition of switchgear sections and distribution circuits without disrupting existing production operations.
Engineered for Reliability, Quality, and Growth
Our engineering team designed a comprehensive power distribution solution that addresses all three challenges with proven technology and thoughtful system architecture.
Redundant Dual-Feed Design with Automatic Transfer
We implemented a dual-power-feed architecture with two independent 10kV utility feeds serving separate bus sections. An automatic transfer switch (ATS) seamlessly transfers critical loads to the alternate feed within milliseconds if a fault occurs on the primary side.
- Dual 10kV utility feeds with independent transformers
- Automatic bus tie breaker with fast transfer logic
- KYN28 MV switchgear with VCB protection
- SCADA monitoring with real-time load analytics
- N+1 redundancy on all critical distribution paths
Active Power Factor Correction & Harmonic Filtering
To address the power quality challenge, we deployed active power factor correction (APFC) systems and active power filters (APF) at key distribution points. These systems dynamically compensate for reactive power and cancel harmonic distortion generated by variable frequency drives and welding equipment.
- APF units for 3rd, 5th, and 7th harmonic mitigation
- Dynamic power factor correction target: 0.96+
- Voltage stabilization within ±2% tolerance
- GCK switchgear with dedicated filter compartments
- Real-time THD monitoring and alarm system
Modular GCK Switchgear with Plug-In Design
Our GCK low-voltage withdrawable switchgear was selected for its fully modular, plug-in design. Each feeder circuit is housed in a withdrawable drawer unit that can be safely removed and replaced without de-energizing the entire panel — enabling hot-swap maintenance and seamless expansion.
- GCK withdrawable design: plug-in feeder units
- Pre-wired spare compartments for future expansion
- Hot-swap capability without full shutdown
- IP40 degree of protection, IEC 61439 certified
- MNS MCC sections for motor control applications
Equipment Delivered for This Project
A complete MV/LV power distribution package — all manufactured, tested, and delivered by GOHO as a single-source supplier.
KYN28-12 MV Switchgear
Metal-clad withdrawable medium-voltage switchgear with VCB breakers, serving as the main 10kV distribution panel. Includes metering, protection, and bus tie sections with SCADA integration for remote monitoring and control.
GCK LV Withdrawable Switchgear
Low-voltage withdrawable switchgear serving as the main distribution board. Modular drawer units for incoming, feeder, and APFC sections. Fully type-tested assembly with high short-circuit withstand capacity.
MNS LV Switchgear for Production Lines
MNS motor control center switchgear dedicated to production line equipment. Includes DOL and soft-start motor feeders, VFD control circuits, and distribution for welding robots, CNC machines, and conveyor systems.
2000kVA Distribution Transformers x4
Four 2000kVA oil-immersed distribution transformers stepping down from 10kV to 400V. Energy-efficient S13 grade with low no-load losses, temperature monitoring, and protection relays. Designed for N+1 redundancy configuration.
Measurable Performance Improvements
The upgraded power distribution system has been operating successfully since commissioning, delivering on every performance metric the client required.
Inside the Manufacturing Facility
A look at our manufacturing process and the equipment supplied for this automotive plant project.
Main Assembly Workshop
GCK switchgear assembly line in our 30,000 sqm manufacturing facility
MV Switchgear Production
KYN28-12 medium-voltage panels under assembly and wiring
CNC Sheet Metal Processing
Precision CNC punching and bending for switchgear enclosures
Busbar Fabrication
Automated busbar cutting, punching, and bending equipment
Quality Testing Laboratory
Routine dielectric and functional testing before product shipment
Final Inspection & Packaging
Final quality inspection and export packaging preparation
Project Equipment Certifications
All switchgear products supplied for this manufacturing project are CQC-certified with complete type test reports, ensuring reliable performance for industrial applications with stringent uptime requirements.
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