The HV Foil Winding Machine is an advanced, indispensable solution specifically engineered for manufacturing high-voltage coils for resin-cast dry-type transformers. Utilizing state-of-the-art tension control and non-contact photoelectric edge correction, this precision equipment ensures stable, consistent winding of copper and aluminum foils. It integrates unwinding, interlayer and end insulation, automatic lead welding, outer surface winding, and precise deviation correction into a single automated workflow. Designed for manufacturers seeking superior coil quality, enhanced short-circuit resistance, and optimized production efficiency, this machine represents the pinnacle of modern transformer foil winding technology.
Product Applications & Suitable Scenarios
This high-voltage foil winding machine is purpose-built for demanding electrical manufacturing environments:
- Resin-Cast Dry-Type Transformer Production: Ideal for HV coil fabrication requiring precise foil layering and insulation.
- Copper & Aluminum Foil Winding: Processes foils of varying thicknesses with wide insulating materials for interlayers and narrow tapes for end insulation.
- Single-Pass Coil Formation: Completes winding, insulation, inner/outer lead welding, and outer surface wrapping in one continuous operation.
- High-Precision Manufacturing: Essential for facilities prioritizing minimal edge deviation, constant tension, and superior dielectric performance.
- Industrial Scale Operations: Suitable for factories aiming to automate foil winding, reduce labor intensity, and achieve repeatable, high-quality output.
Key Performance Features
- Advanced Tension Control: Maintains stable tension during winding, stopping, and unwinding. Pneumatic damping and high-power servo drive ensure constant tension with minimal deviation, eliminating seal changes during winding.
- Servo-Driven Edge Correction: Non-contact photoelectric sensors detect foil edge deviations and dynamically correct via servo mechanism. Correction accuracy within ±0.4mm ensures precise positioning.
- Robust Winding System: Heavy-duty welded steel housing (annealed/stress-relieved) with large-module helical gears (hardened/ground). Variable frequency speed regulation delivers maximum low-speed torque and smooth operation.
- Integrated Insulation & Welding: Automatically winds interlayer and end insulation; completes welding of inner/outer leads and outer surface winding.
- Precision Movement: Servo motor with planetary reducer controls left/right winding movement; presets via touch screen for consistent coil alignment.
- User-Friendly Control: PLC-based system with touch screen HMI; adjustable parameters, real-time monitoring, and button-activated functions.
- High Mechanical Reliability: High-power drive motor with ample reserve; braking function and optimized acceleration slopes enhance operational safety.
Technical Specifications
| Parameter | Specification |
|---|---|
| Equipment Type | HV Foil Winding Machine (Dry-Type Transformer) |
| Primary Application | High-Voltage Coils for Resin-Cast Dry-Type Transformers |
| Conductor Material | Copper & Aluminum Foil (Various Thicknesses) |
| Tension Control | Servo + Pneumatic Damping, Constant Tension |
| Edge Correction | Non-Contact Photoelectric Sensor + Servo, Accuracy ±0.4mm |
| Winding Drive | Variable Frequency, Low-Speed High Torque, Helical Gears |
| Movement System | Servo Motor + Precision Planetary Reducer (Left/Right) |
| Insulation Capability | Automatic Interlayer & End Insulation Winding |
| Welding | Inner & Outer Lead Welding Integrated |
| Control System | PLC + Touch Screen HMI |
| Mechanical Build | Annealed Steel Plate, Hardened Ground Gears |
| Operational Benefit | Single-Pass Coil, High Precision, Reduced Labor |
Operational Workflow
- Uncoiling & Tensioning: The aluminum/copper foil uncoiler uses a servo motor and pneumatic damping to unwind with constant tension.
- Edge Detection & Correction: Photoelectric sensors continuously monitor foil edge position with ±0.4mm accuracy.
- Insulation Feeding: Wide insulating material feeds automatically for interlayer insulation; narrow tape for end insulation.
- Precision Winding: The robust winding system wraps foil and insulation around the shaft with uniform layering.
- Lead Welding & Surface Winding: Machine performs welding of inner/outer leads and wraps outer surface insulation.
- Controlled Stopping: Braking function and acceleration slopes ensure safe, precise stops.
- Monitoring & Adjustment: Operators manage parameters via touch screen with real-time data feedback.
Case Study: Dry-Type Transformer Coil Manufacturing Upgrade
In a specialized resin-cast dry-type transformer facility, the integration of this HV Foil Winding Machine transformed production. After deploying this automated system, constant servo-pneumatic tension control eliminated seal variations, while ±0.4mm edge correction ensured flawless foil tracking. The single-pass process reduced cycle times significantly, while mechanical robustness maintained precision under continuous operation. The facility achieved superior coil density, improved short-circuit withstand, and enhanced dielectric test pass rates.
Conclusion
The HV Foil Winding Machine for Resin-Cast Dry-Type Transformers delivers unmatched precision, automation, and reliability. With advanced tension management, ±0.4mm servo edge correction, integrated insulation/welding, and heavy-duty construction, it is the definitive solution for high-voltage foil coil production. Invest in this cutting-edge equipment to optimize your transformer manufacturing, reduce costs, and achieve superior coil performance. Yibo Machinery remains committed to providing innovative, high-quality winding solutions and global engineering support for the electrical industry.