1. HV wire winding machine
It is suitable for prodcing 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.
What user-friendly solutions do these wire winding machines provide?
Note that these HV wire winding machines are also beneficial due to their level of automation. They can be easily integrated into an existing workflow. Furthermore, customers are provided with remote support solutions in the event of an issue or question.
Once the correct parameters have been entered, all subsequent calculations will be performed automatically. This is advantageous when dealing with demanding workflows. All Tuboly-Astronic wire winding machines are provided with a full lifetime warranty.
Having said this, it is important to take a quick look at what sets these units apart from their competitors.
Strip insulation technology: This allows the conical arrangement of 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 them 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 standardized insulation dimension.
Do not hesitate to contact a team member to learn more about our selection of HV wire winding machines.
2. 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 three models, namely:
- FCCT series winding machines: Uses TIG welding.
- FCCC series winding machines: Use cold pressure welding.
- EFECO series, standardized machine type with either cold or TIG welding process.
What variants of these wire winding machines are available?
The FCCT Series
The FCCT series of wire winding machines for low-voltage tasks is capable of producing round, oval and rectangular coils. Note that this model is equipped to handle both aluminum and copper.
The FCCT likewise boasts a user-friendly edge. This is important in terms of operator orientation and training. A touchscreen will display all pertinent operational parameters. Flexible software packages ensure streamlined integration. Of course, remote support is always available when required.
The FCCC Series
The FCCC series employs cold pressure welding as opposed to TIG processes. Similar to the other wire winding machines produced by Tuboly-Astronic, the FCCC is modular in nature. It can also be programmed via in-house methods or with the help of our team. Note that the FCCC 1000 is capable of addressing foil widths between 200 and 1,000 millimeters.
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 colour touch screen
- Easy to use software with touch screen navigation.
- Easy to set up and maintain.
Contact us to learn more about these LV wire winding machines.
3. HV foil winding machines for dry-type transformers
The FHVT series is suitable for processing aluminium and copper foils 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.
Sliding systems: The FHV series have sliding systems allowing for the winding of 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. This helps to increase production capacity while not sacrificing quality.
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.
The FHVT HV wire winding series offers touchscreen guidance throughout the production process, and intuitive software ensures rapid workplace integration. Remote support, high-quality Swiss manufacturing and automated controls are other features to highlight.
The FHV can accommodate foil widths of up to 200 millimeters and capacities of up to 800 kilograms (the FHVT 200). Coil lengths of 1.8 meters and diameters of up to 1.2 meters are likewise ideal for rapid production environments.
There are also some optional features that may be included when needed. Foil edge treatment devices, a foil cleaning apparatus and a protection paper reminder are three examples. Contact a Tuboly-Astronic representative to learn more.
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.
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 bearings 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
These vertical wire winding machines are available in two configurations: the VP and VF series. The final decision will depend upon operational requirements.
For example, the VP/VF 10 can accommodate weights of up to 10 tonnes and winding revolutions of 20 RPM. Outer coil diameters of 2.2 meters can likewise be addressed. Other features include a side-by-side conductor configuration and up to 10,000 Nm of torque.
More robust tasks may require the VP/VF 30. This variant can support up to 30 tonnes of weight and outer coil diameters as wide as 3.4 meters. Note that the entire VF/VP line can be equipped with optional accessories, such as counter bearings and winding mandrels.
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.
These wire winding machines are modular in nature. Thus, they can be equipped in tandem with existing on-site equipment. They are also appropriate for spaces associated with height restrictions.
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 maintaining their tension. Depending on the type, multiple brakes can be swivelled by 90 degrees to change between horizontal and vertical use.
Winder: Comes with a head and a laterally adjusted tailstock mounted on a common base frame for fixing the winding mandrel.
The HW series of horizontal wire winding machines are equipped with a coil pressing mechanism. This guarantees constant pressure throughout the production process. This also helps to avoid accidental damage to the insulation.
Pneumatically operated pressure rollers can be monitored and controlled by the operator, thanks to a user-friendly touchscreen. Note that it is possible to select from two models: the HW10 and the HW20.
Benefits of the features
- Controlled pressure on the conductor.
- Controlled conductor pressure roller
Contact Tuboly-Astronic to address any additional questions that you may have.
6. Winding machines for instrument transformers
They allow parallel winding of up to nine coils. The application of the insulation material is automated. Furthermore, the material is cut to the exact length, thanks to a series of peripheral and transverse knives.
The WHAN wire winding machine is suitable for medium- and high-voltage instrument transformer coils. Both round and rectangular configurations can be accommodated. Wire diameters between 0.12 and 0.4 are compatible with the WHAN. Furthermore, winding speeds of 1500 RPM help to ensure rapid production without sacrificing accuracy.
These solutions can be customized based upon operational requirements. Features may include a winding mandrel, a hot air heating system, a wire brake and an additional wire guiding unit.
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.
The WHAN offers high winding speeds, and it can wind multiple coils in parallel. Combined with trusted Swiss engineering and a long operational lifespan, these wire winding machines provide an excellent return on investment.
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. All the machines manufactured by our team are vetted to the highest of standards. Customers can, therefore, enjoy superior levels of operational reliability. If you would like to learn more, please contact a Tuboly-Astronic team member at your convenience.