Transformer Winding Machine

About Transformer Winding Machine

The transformer winding machine is a special equipment used to wind transformer coils. In the production process of transformer coils, the winding equipment is divided according to the voltage level or capacity of the transformer. There are automatic windings for winding high and low voltage coils of distribution transformers. Winding machines and foil coil winding machines; there are vertical winding machines and horizontal winding machines for winding large power transformer coils.


Transformer Winding Machine Structure

The structure of the transformer winding machine is mainly composed of the body, the frame, the main shaft mechanism and the tailstock support, the base and other components. Because the transformer coil has a certain weight and needs to bear the external force of beating and shaping during processing, the winding The machine body and frame are made of steel with strong bearing capacity. According to the processing capacity of the model, it is divided into three categories: small, medium and large, and the load-bearing capacity is also different.


Transformer Winding Machine Classification

Choosing the right transformer winding equipment is the key to the production of high-performance transformers. According to different needs, transformer winding machines can be divided into the following types:

1. Automatic wire winding machine

The automatic wire winding machine is a special equipment for winding high voltage coils of distribution transformers. The coil produced by this equipment has compact structure, small volume and high strength. In order to further improve the production efficiency, the speed of the main machine of the new type winding machine is increased from 300rad/min to 500rad/min. The wiring mechanism is increased from a single head to two to three heads, that is, three coils can be wound at one time. Simultaneously adopt multiple wires (up to 4) and wind; increase the radial compression mechanism; independently control the tension of each pay-off reel, so that the winding wires are arranged neatly, the turns are tight and uniform, and the current density is evenly distributed. At the same time, it is equipped with an end insulation unwinding mechanism and a wire tensioning mechanism. The computer can preset a variety of parameters, which can complete the coil winding at one time, greatly improving the degree of automation, and reducing the labor intensity of workers.

2. Foil coil winding machine

Foil coil winding machine is the key equipment for winding low voltage foil coil. Tension control and foil strip correction are the key technologies of foil coil winding machines. The foil ribbon tension of the existing foil coil winding machine is generated by mechanical friction, and its tension is not stable enough, which will cause the winding tightness of the coil to be uneven, the DC resistance between the coils is inconsistent, and the outer diameter of the coil is out of tolerance. .

Nowadays, winding machine manufacturers have developed a new type of digital foil winding machine, which uses a DC motor to generate the tension of the foil. Its characteristics are that the tension adjustment is convenient, accurate, and stable. The tension remains the same throughout the winding process, which can Ensure the winding quality of the coil. In particular, its tension adjustment range is wide, and it is more suitable for winding thinner foil strips without causing damage to the foil strip ends. In addition, the tension motor is in the power generation state when it is under tension, and the generated electric energy can be fed back to the winding motor or the grid. The friction energy consumption of the frictionless braking tension mode is significant in energy saving. Moreover, the control system will automatically calculate the diameter of the coil on the uncoiler, so as to adjust the motor output torque at any time to ensure a constant tension throughout the winding process, which plays a key role in ensuring the quality of the coil. At the same time, the equipment deviation adjustment system adopts a photoelectric analog sensor to detect the edge of the foil tape without contact, and dynamically correct the deviation through the servo motor. The system has high precision, fast response, high reliability and high accuracy of deviation adjustment.

3. Vertical winding machine

The greater the capacity of the transformers used today, the greater the impact on the power grid, and the requirements for their safety are getting higher and higher. The manufacturing quality performance of the transformer requires not only reliable electrical performance, but also more reliable mechanical stability and short-circuit resistance. The stability is mainly manifested in the control of the manufacturing process of the coil, that is, the electromagnetic balance of the high and low voltage coils is required, and the axial turns are tightly distributed and evenly distributed. Therefore, the coil winding process is required to be compressed in the axial direction and wound in the radial direction. The vertical winding machine is used to take advantage of the weight of the wire cake, and the axial direction is naturally compressed, and the radial tension device is used to control the tension. Therefore, vertical winding machines are generally used to wind high-voltage coils in large transformers, and even low-voltage spiral coils are produced by vertical winding machines.

The current vertical winding machine is further developing towards large scale. The original vertical winding machine has a load of only 20t, but it has now been increased to 40t. The maximum coil diameter is 3500mm and the maximum height reaches 4000mm. The airbag plate tension device is used, and the tension is displayed digitally, and the tension control is more accurate, stable and reliable. In order to improve the dimensional accuracy of the coils wound, control the radial runout of the vertical winding machine, and increase the winding die shaft head fixing device; in order to control the axial runout, a high-precision double-row roller type large bearing is used. Therefore, through the use of special equipment for coil winding, the winding production reaches a new level. This makes it possible for the transformer to further reduce losses, reduce partial discharge, reduce weight and reduce costs.

4. Horizontal motor winding machine

From the perspective of transformer winding structure design, not all coils can be produced by vertical winding machines. Such as layer structure, multi-spiral structure coil. If this kind of coil is wound with an ordinary horizontal winding machine, it is wound without any pressure in the axial direction, and the gap between the line segments is very large, like a compression spring. The diameter of the coil becomes larger after being compressed, and there is a gap between the coil and the paper tube, which will cause the axial instability of the coil, and the coil may be damaged in case of axial electromotive force. Therefore, the horizontal winding machine with axial and radial compression has been widely used in the production of large transformer coils. As the performance requirements of transformers are getting higher and higher, the production of general small and medium-sized transformers has gradually begun to use compact horizontal winding machines.

In order to more accurately control the pressing force, the torque motor or cylinder used in the original pressing mechanism to generate pressure has now been replaced by a servo motor. In order to control the size tolerance of the wound coil, a grating ruler is added to detect the coil size online. The pay-off tension of each spool on the multi-axis pay-off car is independently controlled. According to the length of the winding coil, the pay-off car follows the movement to avoid new stress caused by the distortion of the wire and reduce the eddy current loss of the winding.


Features of Transformer Winding Machine

The winding of the transformer pressure winding machine adopts a computer CNC control system, and the spindle is accurately positioned by CPLD decoding and speed measurement. It is also equipped with a constant current chopper to drive the stepping motor. It is fast and precise to ensure the normal operation of the equipment. It is widely used Switching power supply transformers, supplies, inductors, Japanese-shaped transformers and other products are in production.

Transformer winding machines are mainly used in the winding processing of transformer high and low voltage windings. They are mainly divided into automatic and numerical control. Numerical control models are the most widely used equipment at present. Transformer winding machines have undergone several generations of improvements and developments. , Has achieved rapid development in function and processing capabilities.

The structure of the transformer winding machine is mainly composed of the body, the frame, the main shaft mechanism and the tailstock support, the base and other components. Because the transformer coil has a certain weight and needs to bear the external force of beating and shaping during processing, the winding The machine body and frame are made of steel with strong bearing capacity. According to the processing capacity of the model, they are divided into three categories: small, medium and large, and the load-bearing capacity is also different.

The main shaft system is a key component of the transformer winding machine. It uses the power of the motor to amplify and output the torque after multi-stage deceleration, which has met the processing of transformer winding. Generally, it is configured with a structure of motor + reduction mechanism. Generally, it is realized by motor variable frequency speed change or gear shifting of reducer.

The data storage segment of the transformer winding machine has the same sequence of steps from 0 to 999, capable of high-speed forward and reverse winding, accurate number of turns, automatic storage of data when problems occur during use, CNC can monitor and display production conditions, simple setting and convenient operation.

The transformer winding machine is currently the main application model for processing transformer coils.

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