General Motors deploys smart transformer at Michigan plant for 33% more grid capacity

IONATE, a London-based deep-tech energy startup, is bringing a smart transformer technology to a General Motors manufacturing plant in Michigan, giving the automaker real-time control over power conditions as electricity demand puts growing pressure on industrial facilities and the wider grid. The Hybrid Intelligent Transformer (HIT) technology will be deployed at GM’s 900,000-square-foot plant in Romulus, Michigan. The facility is scaling production of 10-speed transmissions for GM’s full-size trucks and SUVs after a $300 million investment to expand its capacity. Unlike conventional transformers that primarily step voltage up or down, IONATE’s system is designed to monitor and manage power conditions while electricity is flowing through the facility. The technology can detect disturbances and respond to power-flow problems in real time, potentially preventing them from affecting manufacturing operations or spreading into the surrounding grid. The system will give GM visibility into power quality and consumption at sub-millisecond resolution. The companies say the deployment is intended to improve the plant’s energy resilience, efficiency and power quality while helping identify issues that could otherwise contribute to outages. Transformers get smarter The deployment marks IONATE’s entry into the US market after projects involving European power grids. It also puts the company’s technology inside a major industrial operation at a time when manufacturers are facing increasing demands for reliable electricity. IONATE’s approach is to upgrade the transformer itself, one of the key points where electricity moves between the grid and a facility. The HIT combines power conversion with monitoring and control capabilities designed to detect, analyze, and address disturbances as they occur. “Deploying the Hybrid Intelligent Transformer with General Motors marks a significant step in reinforcing industrial power infrastructure with solid-state intelligence,” said Matthew Williams, founder and CEO of IONATE. He continued: “GM’s manufacturing operations demand the highest standards of reliability, efficiency, and power quality – and that is what we build for. We are thrilled to launch IONATE’s technology in the U.S. with such a titan of American industry.” The technology is designed to work with existing substations and facilities, potentially reducing the need for lengthy shutdowns or large-scale infrastructure replacements. Power control at millisecond speed The company says the technology can also increase the amount of energy infrastructure that existing networks can handle. In average deployment scenarios, IONATE claims its systems can allow grids to accommodate 33 percent more distributed energy resources, carry 25 percent more power without upgrading poles and wires, and cut wasted power by 6 percent. For GM, the initial installation will use US-standard 3MVA IEEE units that are currently undergoing final testing before deployment. Engineering teams from both companies have worked together on the project, with the possibility of extending the technology to other GM manufacturing facilities. “Maximizing efficiency and resiliency is crucial in GM’s manufacturing system, and it’s why we’re implementing innovative technology to enhance our energy management and the overall grid,” said Luis Cervantes, executive director of manufacturing excellence.The system is also designed to operate as part of a larger network. Each HIT can function as a real-time control node connected through IONATE’s Aurora software platform. This could allow multiple installations to work together, giving grid operators and large energy users greater visibility into power conditions across distributed sites.Recommended ArticlesGet the latest in engineering, tech, space & science - delivered daily to your inbox.With over a decade-long career in journalism, Neetika Walter has worked with The Economic Times, ANI, and Hindustan Times, covering politics, business, technology, and the clean energy sector. Passionate about contemporary culture, books, poetry, and storytelling, she brings depth and insight to her writing. When she isn’t chasing stories, she’s likely lost in a book or enjoying the company of her dogs.