Transformer winding machine is a special equipment used to wind transformer coils. In the production process of transformer coils, winding equipment is divided according to the voltage level or capacity of the transformer. There are high-voltage and high-voltage winding machines for winding distribution transformers. Automatic line winding machines and foil coil winding machines for low-voltage coils; vertical winding machines and horizontal winding machines for winding large power transformer coils. Choosing the right transformer winding equipment is the key to producing high-performance transformers. According to different needs, transformer winding machines can be divided into the following types: automatic wire arranging and winding machines
automatic arranging and winding machines The machine is a special equipment for winding high-voltage coils of distribution transformers. The coil wound by this equipment has compact structure, small size and high strength. In order to further improve production efficiency, the main speed of the new winding machine has been increased from 300rad/min to 500rad/min. The wiring mechanism has been increased from a single head to two to three heads, that is, three coils can be wound at the same time. At the same time, multiple wires (up to 4 wires) are used for parallel winding; a radial compression mechanism is added; the tension of each pay-off reel is independently controlled, so that the winding wires are neatly arranged, the turns are tight and even, and the current density is evenly distributed. At the same time, it is equipped with an end insulation unwinding mechanism and a wire tensioning mechanism. The computer can preset a variety of parameters, so that the coil winding can be completed at one time. The degree of automation is greatly improved, and the labor intensity of workers is reduced.
Foil coil winding machine
The foil coil winding machine is the key equipment for winding low-voltage foil coils. Tension control and foil strip deviation correction are key technologies for foil coil winding machines. The foil tension of existing domestic or imported foil coil winding machines is generated by mechanical friction. The tension is not stable enough, which will cause uneven tightness of the wound coils, inconsistent DC resistance between coils, and excessive coil outer diameter. Poor defects.
Domestic manufacturers have developed a new type of digital foil winding machine. This machine uses a DC motor to generate foil tension. It is characterized by easy, accurate and stable tension adjustment, and the tension is maintained throughout the entire winding process. change, thereby ensuring the winding quality of the coil. In particular, its wide tension adjustment range is more suitable for winding thinner foil tapes without causing damage to the ends of the foil tapes. Moreover, the tension motor is in a power generation state when in tension state, and the generated electric energy can be fed back to the winding motor or the power grid. There is no friction energy consumption in the friction braking tension mode, and the energy saving is significant. Moreover, the control system will automatically calculate the diameter of the material roll on the uncoiler, thereby adjusting the motor output torque at any time to ensure constant tension during the entire winding process, which plays a key role in ensuring coil quality. At the same time, the equipment's deviation adjustment system uses photoelectric analog sensors to non-contactly detect the edge of the foil strip, and dynamically corrects the deviation through the servo motor. The system has high precision, fast response, high reliability, and high deviation adjustment accuracy. According to the available information, the equipment technology is already at the world's leading level.
Vertical winding machine
Transformer winding machine Transformer winding machine
The larger the capacity of the transformer used now, the greater the impact on the power grid. The requirements for its security are also getting higher and higher. The manufacturing quality performance of the transformer requires not only reliable electrical performance, but also more reliable mechanical stability and short-circuit resistance. Stability is mainly reflected in the manufacturing process control of the coil, which requires electromagnetic balance of high and low voltage coils, tight axial turns, and even distribution. Therefore, the coil winding process is required to be compressed axially and wound tightly radially. A vertical winding machine is used to make full use of the weight of the wire cake to naturally compress it axially, and use a tensioning device to control the tension in the radial direction. Therefore, vertical winding machines are generally used to wind high-voltage coils in large transformers, and even low-voltage spiral coils are produced using vertical winding machines.
The current vertical winding machines are further developing towards large-scale. The original vertical winding machine has a load capacity of only 20t, which has now been increased to 40t. The maximum coil diameter is 3500mm, and the maximum height is 4000mm. An air bag plate tensioning device is used, and the tension is displayed digitally. Size and tension control are more accurate, stable and reliable. In order to improve the dimensional accuracy of the wound coil and control the radial runout of the vertical winding machine, a winding die shaft head fixing device was added; in order to control the axial runout, a high-precision double-row roller large bearing was used.
Therefore, winding production is taken to a new level by using special equipment for coil winding. This makes it possible for the transformer to further reduce losses, reduce partial discharge, reduce weight and reduce costs.
Horizontal winding machine
From the perspective of transformer winding structure design, not all coils used can be produced using vertical winding machines. Such as layered structure, multi-helical structure coil. If this kind of coil is wound using an ordinary horizontal winding machine and is wound without any pressure in the axial direction, the gap between the wire segments will be large, like a compression spring. The diameter of the coil becomes larger after being compressed, and a gap is created between the coil and the paper tube, which will cause axial instability of the coil. In the event of axial electric force, the coil may be damaged. Therefore, horizontal winding machines with axial and radial compression are widely used in the production of large transformer coils. As the performance requirements of transformers become higher and higher, compression-type horizontal winding machines are gradually used in the production of small and medium-sized transformers.
In order to control the pressing force more accurately, the torque motor or cylinder used in the original pressing mechanism to generate pressure has now been replaced by a servo motor. In order to control the size tolerance of the winding coil, a grating ruler is added to detect the coil size online. The pay-off tension of each reel on the multi-axis pay-off car is independently controlled. According to the length of the winding coil, the pay-off car follows to avoid new stress caused by the distortion and deformation of the wire and reduce the eddy current loss of the winding.