Technology has transformed the production of transformer coils. The speed of production, precision, and automation are the key focus of modern coil winding machines. Tuboly Astronic has several modern machines for all types of winding jobs, from wire to foil coils. Below is a look into the various series of automatic coil winding machines in our collection.

High-voltage automatic coil winding machines

The machines in this category are suitable for producing coils for distribution transformers. You can use them for a strip or layer insulation. The key features of the automatic coil winding machines in this category are:

  • Strip insulation technology: It helps in the build-up of a conical layer of insulation. The technology ensures automatic filling of the ends of the coil. It also allows you to program each layer to ensure it can withstand the voltage impact it will experience.
  • A guiding unit with a dancer-regulated brake system: The dancer in the wire guiding unit controls the braking system to ensure that the tension of the wire remains constant even in circular or conical shapes. All crucial part is to pre-set the required tension levels from the control panel.
  • Proven flattening unit: Flat wires have a higher filling factor than round ones, which makes them suitable to achieve smaller coil dimensions. This flattening unit helps you achieve this by flattening round wires to an adjustable height.
  • Tuboly Astronic winding software: Modern winding machines are modular and automatic. This support software simplifies the automation coil winding processes by offering an interface for programming the machines. You can use it to automate and control the process from the beginning to the end.
  • Winder: It comprises an AC-motor-driven faceplate and a motorised sliding tailstock. You can opt for a flange or a rotating centre sleeve for the tailstock. 

There are three main series of HV winding machines on Tuboly Astronic, WHC, WHD, and WHL.

WHC automatic coil winding machine series

The WHC coil winding machines are suitable for distribution transformers that can handle 600KVA. They do not need any manual intervention as they come with automatic cutting and reattachment of strip insulation. The Tuboly Astronic software pre-calculates and executes all the required stop points.

You can opt for versions with the following options:

  • A winding mandrel.
  • A pneumatic expansion system for the winding mandrel.
  • A decoiler for full-width insulation.

WHD automatic coil winding machine series

They are suitable for coils that handle up to 3000KVA and use strip insulation. The machines in this series allow for automatic build up of concial layer by strip insulation technologie. This is done simultaneously with winding the conductor. It comes with a separate end filler-inserting unit that makes it easy to achieve the right filler height when using conductors with a large cross-section.

Like the WHC series, they do not require any manual intervention from the start to the end. Some of the available options are:

  • LV coil clamping adapters or winding mandrels.
  • A decoiler for rectangular wires.
  • Overhead round wire de-coilers.
  • Winders with manual swivelling counter bearing.
  • A decoiler for full-width insulation.

WHL automatic coil winding machine series

These machines come with all the cutting-edge features of the other HV coil winding machines but are primarily for full-width insulation.

Low voltage coil winding machines

LV-Coil winding machines

These are machines for winding coils for small and medium-sized distribution transformers. Tuboly Astronic produces two versions of machines for low voltage coils. One series uses cold-pressure welding, and the other TIG welding

The critical features of the FCCT automatic coil winding machine series are:

  • Conductor foil decoiler: A winding machine in the FCCT series comes with one or two foil decoilers with each having a programmed braking system to maintain the tension of the foil. The decoiler also comes with an automatic foil edge control system.
  • TIG welding unit: It is automatically controlled by a guiding system that ensures accurate and fast welding. An integrated motor rotates the unit to make it easy to install and weld a thick foil.
  • Expandable decoilers:. The machine can be equipped with  one or two decoilers.

Available options for FCCT machines include:

  • Protection paper re-winder.
  • Foil edge treatment device.
  • Foil cleaning device
  • Coil unloading device.
  • Insulation edge trimming device.

HV-Foil winding machines

FHV coil winding machine series

Tuboly Astronic leads in the production of automatic HV foil winding machines (FHV series) used for cast-resin transformers.

The advantages of critical features

There are several standard features and benefits of the HV foil winding machines discussed above. The features include:

  • A winder.
  • Two or Three Insulation decoilers.
  • TIG welding unit
  • A conductor foil decoiler with a dancer-controlled braking system.

As a result, some of the advantages of these machines are:

  • Continuous and precise winding process.
  • Constant and controlled insulation tension.
  • Automatic calculation of stop points and lead-outs.
  • Automatic foil-edge control.

Vertical winding machines

VF and VP series

The semi-automatic winding machines are the ideal solutions for producing the coils of power transformers. The main advantage of these machines is the pre-calculation of stop points and automatic bending machines. As a result, they significantly reduce the winding time. They come in two main categories:

  • VP automatic coil winding machine series: They are pit versions of vertical automatic winding machines.
  • VF automatic coil winding machine series: They are the floor versions.

The advantages of critical features

  • Double bending station: It makes it possible to bend one or two CTC or single conductors separately but side by side. The bending points are pre-calculated, but the bending lengths and height are adjustable.
  • Multiple bending stations: It allows bending of up to eight single conductors individually on top of each other.
  • Multiple plate brake: The system works in a manner that makes it possible to wind in both directions.

Horizontal winding machines

HW automatic coil winding machine series

They serve the same purpose as vertical winding machines, with the main difference being the orientation of the workstation. They come with a conductor pressing device, in addition to decoiler systems and multiple plate brake systems.

Conclusion

A modern automatic coil winding machine is the right solution for coil manufacturers who value speed and precision. Tuboly Astronic machines bear not only the Swiss quality and innovative technology but also unlimited remote support.