Automatic winding has become an important part of transformer coil development, providing a maintenance-free process guided by stepless adjustments. Conductor bending is handled automatically, with digital displays offering help and error messages to assist operators. Manual winding still offers a superior degree of control, but it comes with a higher failure rate and greater labour requirements.
Wages drive up the lifetime costs of manual machines, but automatic winding comes at a higher upfront cost. A semi-automatic winding machine offers the best of both worlds, reducing the amount of labour required to run your production line while shortening winding times and improving accuracy as well as quality.
Tuboly-Astronic’s VP and VF vertical winding machine offerings rely on a certain degree of automation for heightened accuracy while simultaneously allowing workers to monitor the winding process for the operator guidance. You can pre-calculate your stopping positions and automate your bending process, during the entire winding process the operator is guided through a series of prompts. This combines the benefits of automation with those of human input.
Software
Manual coil winding is plagued with imprecision, particularly when it comes to conductor tension and manual bending at correct position. Manual determination of the correct bending position and the actual bending process is notoriously time-consuming, a challenge an automated vertical winding machine corrects through automation. Software, in combination with the dual offset bending station, is the heart of the vertical winding machine process. Tuboly-Astronic’s application is Windows-based and compatible with industrial computers.
By measuring your stopping points before you begin the winding process, you can plot your course in detail. The software feeds you data and instructions for every step so that you can craft the perfect process before your production line even begins. This technology also keeps tight control over your winding process, observing all working steps before reporting them to your operators.
Touch screen functionality makes for an intuitive interface that requires very little extra training or computer literacy. To ensure consistent quality, Tuboly-Astronic provides ongoing support, allowing you to customize your machine winding process as comprehensively as you prefer.
Pit or Floor Solutions
Tuboly-Astronic’s vertical winding machine products come in both pit and floor versions. Pit-type options are best for transformer coils. Here, your vertical winding machine is installed below ground so that the mandrel can be automatically lowered beneath floor level. This way, operators can keep working without having to move a platform. Floor-type products are designed whenever a pit is not possible. Both vertical winding machine offerings are safe and ergonomic.
Winder Options
Tuboly-Astronic’s vertical winding machine has a headstock that’s crafted to support winding mandrels. This allows workers to fix a range of different winding mandrels to the faceplate as required. If hydraulic swivelling counter bearings are needed to support the mandrel, a vertical winding machine supports them.
This innovative solution ensures that conductors are wound accurately in both directions at impressive speeds. The winding process can be supported between stop positions. A collection of accessories extends your options, allowing you to incorporate additional decoiler units or winding mandrels into your equipment. The semi-automatic process gives workers full control over entire winding process.
The Benefits of a Vertical Winding Machine
A semi-automatic vertical winding machine is more accurate than manual processes. The ability to pre-calculate stopping positions lets workers automate much of the winding process while offering enough control to plan out manual work ahead of time. The simplest tasks can be achieved at incredible speeds, and conductors can be bent automatically to cut labour hours in half. Automated processes can be operated around the clock. Precision positioning helps you to achieve high quality, accurate linear and motion control.
Results are fully repeatable, producing consistency every time to maximise your build quality. Conductor bending has always been labour-intensive, noisy, and risky to workers. By automating this part of machining, you’ll watch your yields climb and your downtime drop. Our vertical winding machine will improve your bend consistency by relying on the controlled dual offset bending station.
The Tuboly-Astronic vertical winding machine was specifically designed to manage transposed disc windings with single or CTC conductors. Transposition requires you to swap conductor positions periodically.
Double Bending Stations
CTC conductors needn’t be bent individually. A semi-automatic process lets you bend your conductors side by side on a double bending station if you prefer to. Bending heights and lengths are adjustable. Bending positions can be calculated in advance, then executed automatically. Alternatively, a multiple bending station can manage as many as eight conductors, each of which can be individually bent.
Multiple Plate Brakes
A vertical winding machine uses multiple-plate brakes in order to control the conductor tension. These are installed on a rack that can be guided horizontally. The design allows for two-directional winding while simultaneously allowing conductors to be braked more tightly.
Maximising Cost/Performance Ratios
On Tuboly-Astronic winding machines winding programs are loaded via a network connection or a touch screen, allowing you to improve the scale of your production line. A fully-scalable business is a profitable one, and a vertical winding machine will improve your cost/performance ratios as well. Automation is an investment with core returns, delivered through reduced labour costs, improved manufacturing times, and reduced risks.
