Power Solutions (old) – HIMOINSA Factories

GENERATOR SETS - MANUFACTURING

SMART WAREHOUSE

CNC-automated system for efficient material management
Continuous 24/7 operation to maximize production uptime
High-capacity infrastructure for large-scale manufacturing
Real-time inventory visibility and full traceability

PUNCHING SYSTEMS

CNC-controlled punching and laser-cutting equipment
Multiple machines to support high-throughput production
Precision cutting and punching for consistent panel and component quality
Fast processing and efficient plate handling to keep lead times low

PANEL BENDER

CNC-controlled bending with automatic loading and unloading
Built to handle large, heavy panels efficiently
Multiple bending stations (including up/down benders) for flexible production
Supports complex folds with consistent accuracy
Rotating device for smooth handling and faster changeovers

SYNERGETIC BENDING SYSTEM (ROBOT + PRESS BRAKE)

Integrated bending robot synchronized with the panel bender for smooth, automated workflows
High-capacity bending for large-format components
Flexible folding options for different angles and geometries
CNC-controlled press brake for precision bends and short runs
Supports manual loading when needed for maximum versatility

WELDING

ROBOT WELDING

Automated welding for consistent quality on large components
Repeatable accuracy to support high-volume production

MANUAL WELDING

Dedicated welding stations for custom work and smaller assemblies
Rework stations to ensure every part meets our quality standards

PAINTING LINE

Electrostatic powder coating for a durable, long-lasting finish
Multi-step surface preparation to improve corrosion resistance and paint adhesion
Primer + topcoat system for consistent protection and appearance
Fast color changes to keep production flexible
High-efficiency powder recovery to reduce waste

LINE CAPABILITY

Continuous line designed for large components and high-volume throughput
Robust handling system to move parts safely and consistently through the process

SOUNDPROOFING

CNC-controlled cutting and fitting for precise acoustic insulation
High-performance insulation materials to reduce noise effectively
Fire-resistant solutions designed for demanding operating conditions

WATER JET CUTTING

High-precision cutting for complex shapes and clean finishes
Ideal for materials that require accurate, low-heat processing
Supports efficient handling of large-format parts

CANOPY PRE-ASSEMBLY

Dedicated pre-assembly stations to prepare components for final assembly
Insulation and smaller parts are fitted onto painted panels to create ready-to-install subassemblies
Improves efficiency and consistency once units move onto the main assembly line

EXHAUST SYSTEMS & PIPES MANUFACTURING LINE

In-house production of exhaust pipes and components for reliable fit and performance
Built to support a wide range of generator configurations and sizes

OPERATIONS

Cutting and forming
Precision shaping and finishing
Insulation pre-assembly for silencers
Welding and sub-assembly preparation

CONTROL PANELS AND WIRING

High-capacity in-house production of power, control, and distribution panels
Design, assembly, and wiring completed by our own specialist teams
HIMOINSA-developed controllers integrated into our systems
Advanced engineering tools to ensure accuracy, standardization, and traceability

GENERATOR SETS - ASSEMBLY

ASSEMBLY LINE

Streamlined “one-piece flow” assembly for efficient, consistent builds
Conveyor-based line connecting all stations through to final testing
Multiple dedicated test benches to validate every unit
Quality checks throughout the process
Final cleaning and inspection before delivery

DESIGN PROCESS

Our engineers focus on developing generator sets with precision and adaptability, incorporating advanced technologies to meet diverse power demands. From concept to production, every design prioritizes efficiency, durability, and seamless integration.

DESIGN PROCESS

The design process for a lighthing tower involves creating multiple prototype designs, developing validation protocols, and conducting rigorous testing, always prioritizing customer needs. This ensures optimal performance, reliability, and compliance with industry standards, striving to be best-in-class in the market.

FINAL TESTING & QUALITY CONTROL

ADVANCED PERFORMANCE VALIDATION

INTEGRATED QUALITY ASSURANCE & MULTI-STAGE TESTING

Precision Test Center: Dedicated Quality & Control hub featuring 4 specialized high-performance stations
Comprehensive Functional Validation: Rigorous stress-testing of electrical, hydraulic, and structural systems to guarantee peak performance in the field
Compliance & Standards Audit: Final exhaustive inspection against international safety and quality benchmarks (ISO/CE/Environmental)
Digital Traceability & Certification: Every unit is dispatched with documented checklists and a unique digital fingerprint, ensuring 100% consistency

LIGHTING TOWERS - ASSEMBLY LINE

HIGH-EFFICIENCY ASSEMBLY LINE

DIGITAL SUPPLY CHAIN & MULTI-MATERIAL INVENTORY

Multi-Stage Workstations: Optimized assembly line featuring dedicated stations for synchronized mechanical and electrical integration
Specialized Auxiliary Hubs: Strategic off-line stations for high-precision sub-assemblies (small components, canopy modules, and advanced mast pre-assembly)
Smart Material Feeding: Just-in-time delivery of metallic and composite parts to ensure a lean, continuous manufacturing rhythm

FLUID & EXHAUST SYSTEMS INTEGRATION

CERTIFIED SAFETY & LEAK-PROOF HANDLING

Hazardous Material Management: Integrated in-line stations designed for the safe and efficient handling of fuel, coolants, and lubricants
Acoustic & Exhaust Fitting: Precision installation of in-house manufactured exhaust systems to ensure optimal back-pressure and noise reduction
Automated Priming: Controlled systems for initial fluid filling and circuit priming under strict environmental safety protocols

DYNAMIC ELECTRICAL VALIDATION

LOAD-BANK TESTING & PERFORMANCE CALIBRATION

Controlled Load Simulation: In-line load-bank testing capability to validate alternator performance and engine response under real-world operating conditions
Electronic System Calibration: Full synchronization and software flashing of HIMOINSA proprietary controllers for Lighting towers
Rigorous testing of emergency stops, grounding, and electrical protection before the unit moves to final inspection

LIGHTING TOWERS - MANUFACTURING

INTELLIGENT LOGISTICS & SMART WAREHOUSE

DIGITAL SUPPLY CHAIN & MULTI-MATERIAL INVENTORY

Automated CNC Inventory: Integrated system for high-efficiency management of metallic and advanced polymer raw materials
24/7 Continuous Operation: Uninterrupted supply chain to maximize production uptime for high-demand components
End-to-End Traceability: Real-time digital monitoring of every part, from raw material to the final units
High-Scale Infrastructure: Optimized for large-volume manufacturing with zero bottlenecks and smart space allocation

PRECISION CUTTING & PUNCHING SYSTEMS

HIGH-THROUGHPUT METAL FABRICATION

Hybrid Laser-Punching Technology: State-of-the-art CNC equipment for high-speed, high-precision structural fabrication
Uncompromised Accuracy: Precision cutting ensures perfect fitting for all heavy-duty structural panels
Lean Processing: Optimized plate handling designed to minimize lead times and industrial material waste

ADVANCED COMPOSITES & SMART POLYMERS

NEXT-GEN MATERIAL ENGINEERING & LIGHTWEIGHTING

Advanced Material Integration: Incorporation of high-tech polymers and reinforced composites to significantly reduce overall unit weight
Superior Corrosion Resistance: Utilization of non-metallic materials engineered for extreme durability in harsh and saline environments
High-Impact Structural Components: Advanced forming of complex geometries that provide greater flexibility and impact absorption
Sustainable Durability: Focus on long-lasting materials that require less maintenance and improve the tower’s lifecycle

AUTOMATED PANEL BENDING & FORMING

PRECISION STRUCTURAL FOLDING

Smart Loading/Unloading: CNC-controlled bending cycles with automated robotic handling for heavy-duty metal components
Multi-Station Versatility: Up/down bending capabilities for complex geometries and structural frames
Consistent Structural Integrity: Guaranteed repeatability in every fold, ensuring the legendary robustness of HIMOINSA frames

SYNERGETIC BENDING & ROBOTIC STORAGE

AUTOMATED WORKFLOW OPTIMIZATION

Integrated Robot Synchronization: Bending systems synchronized with automatic storage for a seamless, "lights-out" manufacturing flow
Adaptive Folding: CNC press brakes capable of managing both large-format components and high-precision short runs
Hybrid Flexibility: Seamless transition between fully automated cycles and specialized manual operations

ADVANCED JOINING & WELDING

STRUCTURAL BONDING & ASSEMBLY EXCELLENCE

Robotic Welding Cells: Automated high-precision welding for structural consistency and maximum durability of the chassis
Specialized Manual Assembly: Expert welding stations for custom configurations and intricate sub-assemblies
Rigorous Rework Protocols: Quality checkpoints at every station to ensure 100% compliance with engineering standards

PREMIUM PROTECTIVE COATING (PAINTING LINE)

INDUSTRIAL SURFACING & ANTI-CORROSION TREATMENT

Electrostatic Powder Coating: Industrial-grade finish for extreme weather resistance and long-term aesthetic durability
Multi-Stage Pre-treatment: Advanced chemical preparation to maximize anti-corrosion properties and paint adhesion on metallic parts
Eco-Efficient Recovery: High-performance powder recycling system to minimize environmental footprint

ACOUSTIC ENGINEERING & INSULATION

NOISE SUPPRESSION & THERMAL PROTECTION

CNC Precision Soundproofing: Computer-controlled cutting of fire-resistant insulation for a perfect acoustic seal
Water-Jet Cutting Technology: Low-heat, high-precision processing for complex insulation shapes and clean finishes
Thermal & Noise Suppression: High-performance materials designed for the most demanding urban and industrial environments

CANOPY & MULTI-MATERIAL PRE-ASSEMBLY

MODULAR INTEGRATION & HYBRID ASSEMBLY

Hybrid Pre-assembly Stations: Integration of metallic frames with advanced polymer covers and composite mast components
Sub-Assembly Optimization: Dedicated stations for fitting insulation and hardware into ready-to-install modules
Efficient Workflow: Pre-assembled components ensure a faster, more reliable final assembly line for high-capacity production

SMART CONTROL SYSTEMS & WIRING

PROPRIETARY TECHNOLOGY & ELECTRONIC INTEGRATION

In-House Electronic Hub: Full-scale production of power, control, and distribution panels tailored for lighting applications
HIMOINSA Controllers: Native integration of self-developed controllers for seamless hardware-software synergy
Expert Engineering: Specialist teams utilizing advanced CAD/CAM tools for standardized and traceable wiring

FINAL TESTING & QUALITY CONTROL

PRE-SHIPMENT TESTING & QUALITY ASSURANCE CONTROLS

Functional testing to confirm performance before shipment
Final quality inspection against defined standards
Documented checklists to ensure consistency and full traceability

DESIGN

EQUIPMENT CONCEPT

Unlike generator sets and lighting towers, the EHR does not incorporate an internal combustion engine. This directly influences both its design and its installation and operational requirements. In practical terms, the unit requires no fuel installations, needs no oil circuits, has no exhaust system, and requires no sound-absorbing materials, such as rock wool. As a result, it is a quiet and emission-free unit at the point of use.

SYSTEM ARCHITECTURE

From a technical perspective, the EHR consists of a set of energy storage units—namely, batteries—managed by a BMS and connected to power electronics equipment, specifically charge-inverters. The entire system is controlled by HICORE, the proprietary control system developed by HIMOINSA, which centralises the monitoring, operational logic, and functional management of the equipment.

DESIGN AND ENGINEERING CRITERIA

From the outset, the design of the EHR prioritises electrical and functional safety. To this end, protective measures, interlocks and control logic are incorporated to prevent hazardous failure modes and ensure robust, controlled operation. Furthermore, special attention is paid to aspects that directly impact the equipment’s operability and maintainability, such as accessibility for maintenance, cable routing and the modularity of sub-assemblies. This approach enables: A more predictable equipment lifecycle, reduced intervention times and easier servicing operations

STRUCTURAL VALIDATION AND TRANSPORT

From a mechanical perspective, the necessary structural calculations are also carried out to validate the assembly’s strength throughout its service life. This process includes: verification of lifting points, validation of transport conditions, and confirmation that the machine can adequately withstand the expected mechanical and environmental stresses.

OPERATIONAL FLEXIBILITY

The EHR is designed to operate in various scenarios, giving it a high degree of integration versatility. It can operate autonomously, connected to the grid, in combination with a generator set, and also alongside renewable energy sources, such as photovoltaic systems. When the EHR operates in conjunction with a generator set, the operating modes allow for: optimising consumption, reducing engine running hours, applying hybrid operating strategies and meeting peak demand more efficiently. This results in more optimised system management and better adaptation to different load profiles.

BATTERY SYSTEMS - MANUFACTURING

INDUSTRIAL PROCESS

The EHR manufacturing process essentially follows HIMOINSA’s standard industrial workflow for canopy and chassis. Production begins with sheet metal stored in the smart warehouse and progresses through the various stages of industrial processing, always in accordance with the specifications defined for the product. This process includes operations such as: punching, panelling, bending, welding, painting

DESIGN AND MANUFACTURING QUALITY CRITERIA

Each component has been designed by our R&D department in accordance with both the applicable manufacturing regulations and the quality criteria defined by HIMOINSA. The aim is to ensure a final product that meets the required standards in terms of reliability, finish, and durability. This approach ensures: dimensional accuracy, corrosion protection, and durability in service.

KEY FEATURE: GALVANIZED CHASSIS AS STANDARD

As a key feature, the EHR comes with a galvanised chassis as standard, rather than a painted one. This solution offers clear advantages in terms of the equipment’s durability and lifespan: improved corrosion resistance, extended service life of the unit, reduced need for repainting, and helps maintain the aesthetic appearance for longer.

CANOPY CUSTOMISATION

The canopy can be supplied in a range of colours, adapting to the customer’s branding or identification requirements, without compromising either corrosion protection or the high-quality finish.

BATTERY SYSTEMS - ASSEMBLY

PRODUCTION ENVIRONMENT

The EHR is assembled at the production centre in Murcia, a facility specifically designed for the manufacture of this range and equipped to produce hybrid or fully electric towers in parallel. This specialisation of the production environment allows both processes and industrial resources to be adapted to the specific characteristics of electrified equipment, with an organisation better aligned with the integration of electrical, electronic and storage systems

ASSEMBLY ORGANIZATION

Due to the design of the EHR and the modular nature of the product, assembly is not organised as a conventional linear production line, but rather in workstations. This approach allows for greater flexibility in the integration of sub-assemblies, improves access to the different areas of the equipment and facilitates process control at each stage of assembly. Before starting the assembly of the main unit, the electrical panels are assembled at specialised workstations. In this way, they arrive at the main area as sub-assemblies that have already been checked and are ready for integration.

ASSEMBLY SEQUENCE

The assembly sequence begins with the chassis and the fixing of the main structural assembly. In this initial phase, the so-called “structural skeleton” is installed, consisting of the battery rack and the lifting structure. From there, the main subsystems of the unit are progressively integrated: batteries, inverters, electrical panels, cabling and auxiliary components.

PROGRESIVE INTEGRATION OF THE CANOPY

Unlike with generator sets, where the bodywork usually arrives pre-assembled, in the EHR the canopy is installed progressively as assembly progresses. This approach offers several advantages during the process: it facilitates access to the various work stations, allows for intermediate checks and promotes the orderly integration of each subsystem.

FINAL INSPECTION

Once assembly is complete, the unit undergoes bench testing and the relevant quality inspections. This final phase allows for validation of both the system’s operation and compliance with the manufacturing and control standards established for the product.

VALIDATION OF THE PROCESS AND EQUIPMENT PERFORMANCE

PRE-SHIPMENT TESTING & QUALITY ASSURANCE CONTROLS

Operational and performance tests
Battery charge and discharge cycles
Response tests under different load profiles
Verification of coordination between batteries and inverters
Checking the correct operation of the emergency stop
Verification of correct earthing
Review of the settings and selectivity of AC/DC protection devices

FINAL INSPECTION

Mechanical and finish checks
Verification of critical torque values
Inspection of the bodywork’s integrity
Validation of safety labelling
Verification of the relevant markings

TRACEABILITY AND DOCUMENTATION

The entire process is documented using checklists and test records, ensuring full traceability of the equipment and providing a record of the checks passed during manufacture and final validation.

EHR DIGITAL FOOTPRINT

The final stage involves preparing the digital footprint of the EHR. This footprint provides access to the documentation associated with the equipment and facilitates the identification and retrieval of technical and compliance information. Among other details, it provides access to the serial number, technical documentation, applicable compliance documentation and other relevant information relating to the equipment.