Our Winding Machines

The safety and efficiency of electrical machines depend on the coil production process. It is, therefore, essential that one understands the different types of winding machines and their uses. Tuboly-Astronic is a leading manufacturer of coil winding machines. In this guide, we offer insight into the six types of coil winding machines, their key features, and the advantages.

1. HV wire winding machine

It is suitable for creating coils for a distribution transformer. They are ideal for three types of insulation; namely, single strip insulation, double strip insulation, and layer insulation.

HV wire winding machines are available in three models with different strip insulation levels. They are:

  • WHC series winding machines: For coils up to 600kVA
  • WHD series winding machines: For coils up to 3000 kVA
  • WHL series winding machines: Full-width insulation.

Key features

Strip insulation technology: It allows the conical arrangement of the insulation and automatically fills the end of the cone with the same insulation strip(s). The technology comes with dancer-controlled tension that improves the filling factor and reduces radial tolerances.

A dancer-controlled brake system: It maintains the pre-set tension of the conductor by regulating the brakes for various shapes. Consequently, one can achieve a perfect layer even at high winding speeds.

Automatic insulation strip cutting and reattachment system: This system ensures zero stops in the winding process by automatically cutting strips and re-attaching it where necessary. This patented solution is only available on our WHC machine type with one insulation strip.

Flattening unit: It flattens round wires to increase the filling factor. It results in smaller dimensions, less core and conducting materials, and, consequently, the tank volume. The overall benefit of this unit is a significant reduction in the transformer production cost.

Benefits of the features

  • Constant wire tension even when working on different shapes.
  • Constant insulation strip tension
  • Automatic filler insertion at the ends of the conical layer builds on WHD machines.
  • High filling factor.
  • Significant savings on coil materials.
  • Easy to wind both rectangular and round wires.
  • Optimised material storage and purchasing due to standardised insulation dimension.

2. LV wire winding machines

LV wire winding machines

These winding machines are suitable for winding the coils of small or medium-sized distribution transformers or chokes. They are available in two models, namely:

  • FCCT series winding machines: Uses TIG welding.
  • FCCC series winding machines: Use cold pressure welding.
  • EFECO series, standardised machine type with either cold or TIG welding process

Key Features

Conductor foil decoiler: Each decoiler has an automated brake system to ensure constant foil tension. A diameter compensation system keeps the tension always constant. Insulation decoiler: One can install one or two insulation decoilers to maintain the tension of the insulation.

TIG welding unit: It comes with a high-precision automatic guiding unit, an integrated motor, and clamping jaws. The combination makes it easy to create perfect thick foils and an automated welding process.

Cold pressure welding: The most efficient way to connect the conductor foil with the leadouts (busbars). The following functions are automated in the process: grinding for copper foils, pressure adjustment, pressing process and positioning of downholders.

Motor-driven roller knife: It cuts the foil at pre-set points.

Benefits of the features

  • Controlled foil and insulation tension with automatic diameter compensation.
  • Controlled foil edge control
  • Automated programmable stopping points throughout the entire winding process
  • Operator guidance on color touch screen
  • Easy to use software with touch screen navigation.
  • Easy to set up and maintain.

3. HV foil winding machines for dry-type transformers

HV foil winding machines for dry-type transformers

The FHV series are suitable for processing both aluminium and copper foils in order to wind HV coils for mainly cast resin transformers. Additionally, they all come with intuitive winding software. FHV series: They are for winding high voltage coils for cast resin transformers.

Key features

Sliding systems: The FHV series have sliding systems that make it possible to wind single discs continuously and directly onto the casting mould.  Precise dancer controls: Enables efficient and high-quality winding by maintaining a constant tension of the foil and the insulation.

Automatic winder unit: It has a sliding frame system that holds the head and adjustable tailstock. The unit automatically shifts to new disc positions during continuous foil winding.

Automated TIG welding unit: It automatically welds the conductor foils to the leadout or disc connections. The welding positions and the speed of the welding torch are pre-calculated.

Benefits of the features

  • High-quality continuous winding due to the precise sliding system.
  • Constant foil and insulation tension.
  • Automated highly precise TIG welding system.
  • Automatic foil edge control system.
  • Easy pre-calculation of stop points.

4. Vertical winding machines

They are suitable for the production of transposed disc windings of power transformers. Its winding software calculates all the necessary stop points and bending, leading to a fully automated production process.

Key features

Different versions: Vertical winding machines are available in safe and easy to use floor or pit versions.

The winder system: It has a headstock that supports different types of winding mandrels. Optional counter bearing are available upon request and depend on the actual used winding mandrel.

Double bending station: It allows side by side bending of conductors with adjustable bending lengths and heights. The bending position calculation and the bending process are automated.

Multiple plate brake: It allows winding in both directions, guarantees a constant conductor tension during the winding process and tightens the down disk.

Multiple bending station: The feature allows the bending of up to eight single conductors individually at the same time. Like the double bending station, the bending heights and lengths are adjustable, but the position and the execution are automated.

Benefits of the features

  • Automatic bending of conductors
  • Pre-calculated stop positions (for any position)
  • Highly precision production

5. Horizontal winding machines

They are suitable for winding the coils of power transformers. The machines come with highly precise automation software for the careful processing of standard conductors and heavy-duty applications.

Key features

Decoiler systems: Different decoiler systems are available for various coil requirements from single to multiple decoilers.

Multiple brake plate: Helps in separating paper insulated conductors and maintain their tension. Depending on the type, the multiple brakes can be swivelled by 90 degrees to shift from horizontal to vertical use and back.

Winder: Comes with a head, and a laterally adjusted tailstock mounted on a common base frame for fixing the winding mandrel.

Benefits of the features

  • Controlled pressure on the conductor.
  • Controlled conductor pressure roller

6. Winding machines for instrument transformers

They allow parallel winding of up to nine coils. The application of the insulation material is automated.

Key features

Separation knives: They are placed between the coils to separate them from each other. Trimming knives: They are two knives that trim the edges of the outer coils.

Benefits of the features

  • Fully automated process, from insulation insertion, cutting, coil separation, and trimming.
  • Controlled conductor tension.
  • Winding multiple oils in parallel.
  • High winding speed.

Conclusion

The above are the primary type of machines used for coil winding and their uses. Check the product leaflet for additional information on the features and ways to make use of them.