Automatic transformer winding machines offer electrical component and industrial electronics manufacturers various production and quality advantages, not least:
- Lower failure rates, both during and after assembly.
- Precise conductor blending and spacing.
- Lower production costs than with a manual machine or by hand.
As a secondary benefit, automated winding machines tend to deliver results that are much more consistent than manual processes. In turn, this uniformity produces greater standardisation in the dimensions of insulation materials. As a result, optimisation in material storage and purchasing arrangements could give rise to cost savings.
In contrast, although manual techniques do offer an enhanced level of control, their disadvantages include:
- A relatively high incidence of failure of the transformer windings.
- Less accuracy in coil positioning, thus leading to variations in electrical characteristics and performance.
- Higher expenditure on manual labour.
To discover more about the advantages of automatic transformer winding, read on. Below, we discuss how electrical manufacturers can ensure consistent quality, optimise production and minimise overall costs in the medium to long term.
Semi-automatic transformer winding machines
Offering the best of both the above worlds, semi-automatic transformer production machines feature increased operator control. In effect, they bridge the gap between manual and fully automated systems. While maintaining accurate positioning with precise start and end positions, their control systems prompt operator(s) for confirmatory inputs during manufacturing.
In comparison to manual methods and imprecise winding, the automatic calculation of winding start and endpoints maximises production efficiency. Specifically, semi-automatic machines can calculate precise turning and stopping positions, thereby reducing task initialisation by up to a half. In short, semi-automatic vertical winding machines improve winding processes and the quality of the results. Thanks to microprocessor control, their inherent uniformity and reliability also reduce costly errors, material wastage and unproductive working time.
Transformer Winding Machines with PC Control Systems
Any commercial operator that relies on winding machines for their transformer products can trust the precise engineering and quality available from Tuboly Astronic. Our horizontal machines, for example, are specifically designed for the winding processes needed for the demands of modern power transformers.
Not only do our machines have a novel modular design, which means they can be adapted to all scales of applications, including heavy-duty ones, but they are also packed with addmer winding machine itional features that allow operators to remain in full control at all times, too.
Among these measures are our PC control systems, which assist with the smooth running. Indeed, all of the winding data that is collected can be easily transferred to experts inside and outside of your company for further analysis. Furthermore, our tailored accessories help to make sure that you can benefit from the latest technologies in numerous ways. Read on to find out more about the use of PC control systems in transformer winding machines and the associated technologies that go with them.
The use of PC Control Systems in Transformer Winding Machines
Today’s generation of transformer winding machines is able to ensure that all standard conductors are produced correctly and within even the tightest levels of quality control. This is largely achieved by the sort of PC control systems that can be put in place to keep an eye on all of the winding processes as they are carried out. Such telemetry is specifically designed to cope with the demands of transformer winding machine manufacturers and the individual products they make, whether it is power transformation devices or the parallel winding requirements of modern instrument transformers.
For example, our automated transformer winding machines are often used to produce coils for distribution transformers. In fact, we make such systems to provide both strip or layer insulation within a PC-control system setting. Our computerised automatic coil winding machines help with the build-up of an extremely precise conical layer of insulation. The computer technology that comes with our high-voltage transformer winding machines helps to make sure that automatic filling of the termination of each coil is also maintained; not all transformer winding machines provide this level of functionality.
Another key factor regarding Tuboly Astronic PC control systems is that they allow users to program each layer of their coils independently, enabling functionality to be utilised in the way that is deemed best for your business. Additionally, we find that this high level of accuracy with coil layer programming means that the end product is better able to withstand the level of impact it will experience from the voltage it is exposed to over the course of its working life. At Tuboly Astronic, we have developed the necessary winding software you might need to produce this level of precision.
Although today’s transformer winding machines are usually modular in their design, not all are automated or designed to work hand-in-glove with PC-controlled software packages. This makes our current products stand out from competitors. In fact, our software systems are specifically designed to support your daily operations in a number of ways, including simplifying the automation of coil winding processes, which can be repeated precisely at a later date by using the same settings. Our software will also help efficiency by offering a more rational and user-friendly interface for changing your preferred machine settings.
In fact, many of our clients use our software to automate their entire transformer winding processes from beginning to end. You are under no obligation to do the same if you already have manual processes that work for you, of course. That said, the ability to control our machines quickly, easily and repeatedly with our software from nothing more complex than a standard PC will often make a huge difference to a transformer manufacturer’s productivity.
What Other Features Does Tuboly Astronic AG Offer with its Transformer Winding Machines?
Given the features available with our PC-control systems for our transformer winding machines, you may wonder what other technology goes into our products. Typically, a transformer winding machine made by Tuboly Astronic will include things like LV coil clamping adapters or winding mandrels. Other functions include the ability to make use of our manually swivelling counter bearing winders.
Overhead round wire decoilers are another important feature worth mentioning, as is the ability to make use of a decoiler for full-width insulation. All of the aforementioned features come with our WHD range of automatic transformer winding machines, which are capable of forming coils that can handle loads of up to 3000 kVA. A similar range is our WHC coil winding machines.
These are suited to distribution transformers that can handle loads up to 600 kVA, They are supplied with a useful pneumatic expansion system for the winding mandrel. In terms of PC controls, the WHC range is fully compatible with our software, which can be used to pre-calculate all of the necessary stop points in your product design.
The Advantages of PC Control in Modern Transformer Winding Technology
Much of the manufacturing sector currently benefits from data collection and computerised control systems. At Tuboly Astronic, we are aware that PC control systems are what transformer winding machine manufacturers are increasingly demanding in order to keep with this trend. Of course, the biggest advantages of using computers in manufacturing is to maintain a high standard of quality control.
When transformers – or any manufactured product, for that matter – fail, it is commonly down to a fault that occurred in the manufacturing process and not all manual quality control measures will be able to pick them up. However, when PC control systems are in place, fewer errors are made when a product is put together. With greater precision and less reliance on human intervention, productivity and quality should rise in tandem.
In short, this means fewer interruptions to your transformer production line to fix issues, earlier identification of problems when they do occur and fewer returned products. This means keeping your clients happier with the products they receive from you along with all the attendant benefits that will facilitate business growth. Ask yourself this: If you can take advantage of the sort of software and automated PC control systems offered by Tuboly Astronic nowadays, why wouldn’t you?
Features of transformer winding machines
Typically, today’s generation of transformer winding machinery boasts the following options:
- Touch screen functionality and ease of operation.
- Intuitive interface software.
- Reduced noise levels during operation.
- Customizable processes, thanks to the increasing adaptability of PLCs (programmable logic controllers).
- A high level of precision in linear positioning during their winding motion.
- Flexibility: Able to wind either round or rectangular wire.
- Consistency in the flexing and bending of conductor material.
- High filling factor, due to built-in flattening units that compress round wires.
Depending on the machine, flattening units can roll even enamel-insulated round wires to an adjustable height. Flattened wires lead to a higher coil filling density and, overall, smaller dimensions for the same electrical performance. Furthermore, less conductor core material is necessary and tank volume is lower, thus reducing manufacturing costs. Notably, levels of specification vary according to the model.
What to look for
Given the advantages of transformer winding machines, you may be wondering how to choose the best model for your business. Below, we set out the various factors to consider before making your purchase decision. Firstly, during their winding cycle, high-quality motor-driven machines expose the coil conductor wire to constant tension and uniform torque. In the same way, they keep insulation strips under steady pressure.
Additionally, dancer-controlled brake rollers minimise or do away with variations when working on different core shapes. Importantly, the above uniformity ensures consistently high quality, both in product appearance and – crucially – in operation. It ought to be easy to wind both rectangular and round wires, whether high or low voltage. A robust and high-performing machine will ensure tightly, evenly-wound coils which, in turn, help to reduce magnetic flux leakage.
In machines that have wire guiding and dancer-regulated brake systems, the pre-selectable wire tension remains uniform. Even with rectangular or oval transformer coils, or high winding speeds, the layers of coil wire will be level. It is also possible to adjust the wire tension from the control panel, usually without mechanical intervention. When conductors have a large cross-sectional area, good manufacturing practice requires inserting end filler strips.
To address this, machines insert the additional insulating strip via a separate guiding mechanism. This is done in parallel with the two standard insulation strips. Notably, the computerised mechanism calculates the appropriate end filler height and automatically cuts the precise length of strip required. WH type machines are able to insert filler automatically at the ends of conical layers. Apart from significant time savings, this capability also standardises the appearance of the end product.
When purchasing, machine specifications and performance capacity are of primary importance. It is advisable to check the speed of operation, taking envisaged production targets into account.
Other essential considerations include the:
- Manufacturer warranty, reputation and perceived machine reliability.
- Ability to use the desired gauge (diameter) of wire, taking into account the product and coil dimensions
- Automated calculation of winding stop points to accommodate cooling ducts, taps, etc.
- Installation and commissioning costs and timescales.
- Availability of remote technical support to resolve queries.
- Possibility of on-site engineering visits and call-out if necessary, to minimise downtime.
- Total cost of ownership, including periodic safety inspections.
- Running costs including operator(s), electrical supply and insurance.
- Anticipated return on investment.
- Capital allowances and other tax incentives available.
Here at Tuboly-Astronic AG, we have been developing and producing electrical transformer winding and manufacturing machines for three decades. Business customers can count on our depth of knowledge and experience within the industry. We guarantee the highest design, functionality and performance standards of our products. From hardware and software to system integration and service provision, we achieve the highest possible quality and efficiency.
Built for lengthy service, our transformer winding machines feature ergonomic designs, state-of-the-art software and quick, intuitive set-up. Programming is straightforward, while operator guidance is via touch screens. Are you a decision-maker in the coil winding, core manufacturing or industrial manufacturing sector? Engineering firms and manufacturers can count on an enhanced degree of reliability with Swiss quality. To discover more or discuss your requirements, please contact us today.
*Footnote: To prevent further unwanted power losses, transformer cores often feature thin steel laminations, which minimise eddy currents.