At Tuboly Astronic, our expert Swiss engineering team has been developing high-tech machinery designed for the production of transformers for the last three decades. This means we have gained a great deal of knowledge about the sort of features and specifications that users of modern coil winding machines seek. Consequently, our knowledge and expertise are shown in the hardware we produce for our world-class coil winding machines – but it doesn’t end there.

You can also find our industry experience being brought to bear with the software and system integration options we provide. We aim to equip our clients with features that can bring about the highest possible efficiency. When it comes to coil winding machines, we think that you will find no more reliable systems than those we design and manufacture. Nor will you be able to beat the particular array of machine features on offer from within our ranges. Read on to find out the specifications appropriate to your needs and why our range is world-leading.

The Coil Winding Ranges Made by Tuboly Astronic

A WH Series Wire Winding Unit with Full-Width Insulation

Before discussing all of the features and specifications you might expect from one of our coil winding machines, it will be worth examining the Tuboly Astronic range. Not only do we manufacture special machines for our clients to meet exact specifications for their particular requirements, but we also produce core manufacturing systems.

Among the core manufacturing options on offer are stacking systems and core cutting lines. However, we are probably best known for the features found in our highly rated coil winding machines. Within this range, you will find both horizontal and vertically arranged coil winding systems designed for industrial use. Tuboly Astronic’s expert engineers also design a fantastic array of foil winding machines, of the HV and LV varieties.

We make feature-rich systems for instrument transformer winding as well as three product ranges for different types of HV coil wire winding; the WHD series, the WHC series and the WHL series. As such, there is an incredible amount of choice for products within our ranges. The degree of versatility on offer is even greater when you consider all of the optional features and particular specifications available within our extensive product range. Let’s examine a few of those features in more detail to give you a better idea.

Wire Guiding Units and Dancers

Our superb dancer systems are features that nearly all of our coil winding machines can be supplied with from day one. These devices regulate the motor-powered brake rollers of your winding unit. As such, they help to maintain the pre-selected wire tension at a constant level and can do so without physical intervention, simply by adjusting the control panel. In addition, they can be used to produce oval or even rectangular coil shapes if that is what your winding project calls for. These wire guiding units and their corresponding dancer-regulated brake systems will bring about a superb layer build-up even when high winding speeds are in operation.

End Filler Insertion Systems

This is a feature found in many of the wire winding systems produced as Tuboly Astronic. In cases where a large conductor cross-section may be built up by the coil winding machine, an end filler strip system can be offered. In short, this will be inserted via a separate guiding unit over and above the two usual insulation strips.  These systems are incredibly reliable and, to obtain the desired end filler height, the required amount of end filler strip can be calculated for you. This is conducted by our own machine software system and will even be cut automatically for excellent results every time. 

Flattening Units

Flattening units constitute a popular feature, which means that round enamel insulated wires can be rolled flat. What’s more, they can do so with an adjustable height, which makes them incredibly versatile for all sorts of coil winding jobs. The main benefit of flattening round wires during winding is that a higher filling factor can be achieved. This results in smaller coil dimensions and a reduction in the amount of conductor material being used. Flattening units also result in lower tank volumes. This can add up to significant savings in transformer manufacturing costs. 

Foil Winding Machine Features At a Glance

Foil Winding Machine Features At a Glance

Avoiding unnecessary loss in foil winding is a big issue in the transformer production industry. Our FCCT series of foil winders deal with this in a number of different ways. These machines are specified to run at either 20 or 25 RPMs, depending on the system chosen. As well as helping to maintain an even foil winding process, this means that coil diameters of up to 900 mm can be achieved without significant loss.

Furthermore, our FCCT winding systems can be fitted with either one or two foil decoilers. These operate with a separate foil edge control system for even better results. Other features you can expect of these advanced winding machines include a motorised roller knife. This can cut foil at pre-calculated positions. We also offer remote support and diagnostics and up to two extendable insulation decoilers. In short, our foil winding systems are just as feature-rich as our wire coil winding machines.

An Overview of Vertical Coil Winding Machine Specifications

The Sort of Vertical Winding Systems Available from Tuboly Astronic

Running in a suitably specified PC that is installed with Windows, the winding system software is capable of pre-calculating all the required stopping points you might want with a vertical coil winding machine. This package will oversee the entire winding process with working steps reported to the operator as required. When working in a vertical arrangement, different winding mandrels may be beneficial.

Our VP and VF series of vertical coil winding machines are equipped with a faceplate that allows for many mandrels to be used. Another important feature is that a hydraulic swivelling counter bearing can be used to offer augmented support to the mandrel. Other things our customers can specify in our vertical winding systems are double bending stations, multiple bending stations and multiple plate brakes, as required. With pressing forces of up to 20,000 N catered for and various other accessories on offer, the sky is the limit with these machines.

Summing Up

If some of the features and specification options described in this article will benefit your business, then do not hesitate to get in touch with us. We will be happy to discuss your requirements and see how we can help. Just complete our contact form for a professional response.